Project: Duckie   -  
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Builder Name:Robert Schmid   -  
Project:   Quickie - Q2   -   VIEW REPORTS
Total Hours:1219
Start/Last Date:Apr 29, 2022 - Aug 31, 2023
Engine:O-200
Propeller:Catto
Panel:Falken Avionics, Uavionics AV-30, BendixKing AP, iPads
 
Friendly URL: https://eaabuilderslog.org?s=Duckie

Home or Last Project Picture

Apr 09, 2024     Added air filter - (2 hours)       Category: Engine
Removed 90 degree nozzle towards front air inlet
Added K&N filter with aluminium tube extension


 
Apr 08, 2024     Added baffling to cylinders #1 and #3 - (2 hours) Category: Engine
Added more cover for the #1 and #3 cylinders to bring temperatures HIGHER and bring in line with #2 and #4 ... needs testing
 
Apr 06, 2024     Various Little Updates - (2 hours) Category: Paint / Decals
Fixed cowling nutplate that was bending and falling off
Sanded down inside of cowling where rubbing happened
Reinstalled tire pressure sensors
Refilled brake reservoir
 
Apr 06, 2024     Completed Piston/Cylinder Upgrade - (10 hours)       Category: Engine
Finished wiring cleanup
Installed baffling
Installed plenum
Installed cowling
Did 1hr test flight
CHTs good for cylinders 2,3,4, never above 380
CHT for cylinder 1 too low, never hit 300 ... removed metal tape on front inlet
Oil temp went too high at 225 ... removed lower inlet blocks, removed throttle body elbow and increased outlet opening at bottom end of cowling
Had lower spark plugs fouled, so removed, cleaned and reinstalled them


 
Apr 05, 2024     Continued piston/cylinder upgrade - (12 hours)       Category: Engine
Measured valve lash, all within tolerance, mostly in the 70s
Installed valve covers and tidied up loose items
Test ran engine for leaks, no leaks found
Removed previous CHT sensors
Disconnected EGT sensors as bundled together with CHT sensors
Resoldered all EGT & CHT connections, with new shrink tubing ... solder joints / sensor readings need monitoring
NOTE - right side bundles are #1 EGT & CHT, #3 EGT & CHT, left side mixed up #2 EGT with #4 CHT, #4 EGT with #2 CHT
Re-bundled all wires
Replaced all spark plugs with new ones
Mounted CHT sensor rings on underside underneath the 18 to 14mm adapters
Torqued adapters per SDS manual
Replaced valve covers with newly cleaned, sand blasted and painted covers


 
Apr 04, 2024     Upgraded pistons/cylinders with High Compression - (12 hours)       Category: Engine
Took off cowling, plenum and baffling
Took off bottom parts, intake tubes, pushrod tubes and exhausts
Removed cylinders and pistons
Installed new pistons and cylinders
Discovered need for different CHT sensors, no ports for bayonet style sensors ... Ordered 18mm sensors
Reinstalled all bottom parts
Tried to deflate hydraulic lifters to install rocker arms but inflated again too fast
Pushed in valves instead and then installed rocker arms


 
Aug 27, 2023     Finished paint & decals - (20 hours)       Category: Paint / Decals
Touchups with paint
Cowling painted
Vinyl applied
Decals applied
Headrest with embroidery installed


 
Sep 01, 2023     Upgraded Falken FDC to v3 - (20 hours)       Category: Avionics
Uninstalled all USB equipment and wiring
Rewired everything to serial
Installed new GPS
Installed new FDC
Tested all and installed a bunch of firmware updates


 
Jun 22, 2023     Made & installed aluminum baffles - (4 hours) Category: Engine
Replaced metal tape with metal baffles
Baffles are for undersides of cylinders, both front and rear
Baffles are held in with safety wire
Also added significant metal tape around cyl #4 front
 
Jun 20, 2023     Replaced ELEVATOR springs - (2 hours) Category: Controls
Replaced lighter springs with STRONGER stock springs
 
Jun 22, 2023     Tested EGT & CHT sensors for temp differences - (1 hour) Category: Avionics
Put all sensors in same hot water and checked for consistent temps ... ALL OK
 
Jun 22, 2023     Fixed EGT #2 connection - (4 hours) Category: Avionics
Had a "Wackelkontakt", a loose connection, at the solder joint for cylinder #2 EGT which also included cylinder #4 CGT probe
Re-soldered BOTH connections
Redid lots of zip ties
 
Jun 09, 2023     5 Hour Inspection - (4 hours) Category: Inspection
Compression - #1 68/80, #3 75/80, #2 76/80, #4 74/80
Top Spark Plugs - Clean; Bottom Spark Plugs - Clean
Looked into cylinders with little camera - Looking good from what we can see
Torqued spark plugs back to 25-30 outer rings, 18-22 plugs itself
Changed oil filter Tempest AA408108-2

 
Jun 07, 2023     Added metal tape covers on front cylinders - (1 hour)       Category: Engine
Found significant temp differences between front and pack cylinders
Added tape on front to get better flow in back


 
Jun 06, 2023     Added sparrow strainers to elevators - (6 hours)       Category: Wings
Had to hold significant back pressure
Decided to add carbon sparrow strainers


 
Jun 06, 2023     Calibrated fuel sensors - (8 hours) Category: Fuel System
Found main fuel sendor to be not calibrated
Removed sender from tank, rebent slightly to point AFT, not sideways
Calibrated on bench with Westach instructions for manual calibration
Reinstalled sender
Calibrated main sender with V values ... Good values up to 12 gallons
Calibrated header sender ... Good values all the way to 5 gallons, room for one more gallon most likely
 
Jun 06, 2023     Changed light spring for one side to stronger - (1 hour) Category: Controls
Experienced stick back pressure needed so added stronger spring
Decided to also add sparrow strainers
 
Jun 04, 2023     Prop Balance - (2 hours) Category: Propeller
Done by Jeremy
Read 3.6 at start, improved to 1.5-1.6 with one weight taped to inside of flange
 
Jun 03, 2023     FIRST FLIGHT - (1 hour) Category: Inspection
We, well Eric, did the first flight today and most things worked well
 
Jun 03, 2023     Swapped tires for better balance & fixed rotor wobble - (4 hours) Category: Landing Gear
Took out tires and saw significant flat spots
Replaced tires with other old tires but in better shape
Tightened rotor bolts to achieve best true alignment
 
Jun 03, 2023     Swapped tires for better balance & fixed rotor wobble - (4 hours) Category: Landing Gear
Took out tires and saw significant flat spots
Replaced tires with other old tires but in better shape
Tightened rotor bolts to achieve best true alignment
 
Jun 02, 2023     Installed air vent - (3 hours)       Category: Interior Finish
Connected flex hose to NACA vents on each side ... PIA placing and stuff in the way
Drilled and floxed in carbon tube to NACA vent for iPad mount air
Connected silicon hose from NACA vent carbon tube to iPad mounts


 
May 29, 2023     Installed new brake pedals - (8 hours)       Category: Controls
Made new brake pedals out of stronger materials
Put a vertical bend on them for extra strength
Re-installed new pedals with brake cylinder mounted at the rear of bracket


 
Jun 01, 2023     Tested Static & Pitot - (2 hours) Category: Avionics
With JRs help, tested that both pitot and static ... seems leak free but found significant speed differences between Falken and AV-30
 
May 30, 2023     Fixed safety wiring on prop - (1 hour)       Category: Propeller


 
Jun 01, 2023     Labeled fuel fill - (1 hour)       Category: Paint / Decals


 
May 31, 2023     Polished wing, canard and installed VGs - (3 hours)       Category: Wings
Used Marine polish and paint came out amazing
VGs look way aft but its according to plan
Went with 20 pairs of VGs per side, following Jason Skiby recommendation


 
May 28, 2023     Checked travel for all control surfaces - (2 hours) Category: Controls
Measured against POH numbers
Elevator travel more than in POH ... OK
Aileron travel a little uneven between up and down
Rudder travel OK
Compared with Jim P who is less travel than we do
 
May 27, 2023     Polished canopy glass - (8 hours)       Category: Interior Finish
What a PIA
Used sanding system from ACS first
Then used polisher from Harbor Freight with other #3 and #2 polish out of bottle


 
May 27, 2023     Moved GPS for better reception - (2 hours)       Category: Avionics
Taxi test showed that under glare shield I loose reception
Moved on top of glare shield by drilling hole and glue down with contact cement


 
May 27, 2023     Safety wired bolts - (1 hour)       Category: Propeller
Bolts have special nuts but safety wiring just in case
Eric re-did mine, in nice 2 bolts at a time pattern


 
May 29, 2023     Label fuel fill - (1 hour)       Category: Paint / Decals
Added label per D.A.R. instructions


 
May 25, 2023     Airworthiness Inspection PASSED - (2 hours)       Category: Inspection
HURRAY!!!


 
May 24, 2023     Connected & installed air filter - (3 hours)       Category: Engine
Cut & floxed in a screen
Connected throttle body with canopy inlet with baffling material
Cut foam filter material and stuffed into air intake


 
May 24, 2023     Installed Fobo BT pressure gauges - (2 hours) Category: Landing Gear
Left one has a bad thread but Chris got it on
 
May 24, 2023     Installed N number, Experimental & Data Plate - (1 hour)       Category: Paint / Decals


 
May 19, 2023     Redid brake lines - (8 hours)       Category: Landing Gear
Redid brake lines with aluminium tubing vs plastic
Fixed bend away from wheels


 
May 10, 2023     Redoing tailwheel geomotry & cleanup - (8 hours)       Category: Inspection
Reran cables on bell crank
Safety wired all cable connections
Cleaned fuel filter before fuel pumps ... very little build debris
Cleaned up zip ties behind seats and inside cone
Plus another taxi test


 
May 06, 2023     2nd Taxi Test - (8 hours)       Category: Controls
Did some longer taxi tests we redone cable/rudder/tailwheel geometry
Steering was good, tailwheel broke free when expected
Some EFIS bugs, reported to Falken
Brake hose leaked in right wheel resulting in redoing brake lines inside wheel pants


 
May 06, 2023     Installed canopy gas strut - (4 hours)       Category: Interior Finish
Floxed in 2 attachment points that don't interfere with carbon bar across
Went with 40lbs force strut from Amazon


 
May 05, 2023     Redesigned, rewelded and reinstalled new rudder pedals - (20 hours)       Category: Controls
Redesigned pedals with full 5/8 torque tubes and U shaped pedals
Had Don Houseman weld them for me
Reinstalled them, plus special bolt on stops against sideways sliding


 
May 01, 2023     Fixed rudder wobble - (3 hours)       Category: Controls
Changed bold to 5mm
Added bushing at top
Shortened bottom spacer
Widened stop slots


 
May 01, 2023     Mounted missing plug hoods - (1 hour)       Category: Avionics


 
May 02, 2023     Covered all thru holes with silicone - (1 hour)       Category: Avionics
Instead of grommets, put silicon around all wires running through bulkheads


 
May 02, 2023     Strengthened tailwheel spring - (16 hours)       Category: Landing Gear
Sanded tail spring for good transition
Added 2 layers of UNI and 2 layers of BID, then vacuum bagged
Added 2 more layers of BID for cosmetic round look
Drilled out tailwheel attachment from 5/8 to 3/4
Floxed tailwheel back onto larger spring


 
Apr 23, 2023     Completed a W&B - (2 hours)       Category: Inspection
Comes out to 699lbs after subtracting 2 gallons of fuel at 12lbs
Updated W&B spreadsheet ... https://bit.ly/DuckieWAndB


 
Apr 28, 2023     Finished brake install - (4 hours)       Category: Controls
Changed spacers from washers to custom CAD spacer
Safety wired brake disc bolts
Replaced & safety wired brake caliper bolts
Replaced all brake caliper bracket to pants bolts, added 3rd bolt on both sides
Added FOBO BT pressure sensor


 
Apr 27, 2023     Installed canopy lock & safety mechanism - (4 hours)       Category: Fuselage
Used stock design, made CAD drawings and had it cut at Xometry.com


 
Apr 27, 2023     Mounted batteries in tail - (4 hours)       Category: Instrument Panel
Made fiberglass walls and fiberglassed in strap holders
Taped batteries together
Need to still connect trickle charging wires


 
Apr 28, 2023     Ran static & pitot lines to Falken - (2 hours)       Category: Instrument Panel
Eric climbed into tail to connect to static ports
Ran lines forward and connected straight to Falken for now ... missing y splits for AV30 and AP head


 
Apr 28, 2023     Redesigned rudder pedals for strength - (3 hours)       Category: Controls
Discussed current pedals with team, Don Houseman (welder) and JR
Decided to go with U pedals and 5/8 continous torque tubes


 
Apr 23, 2023     First Taxi - (4 hours)       Category: Inspection
Lots of learnings ...
- swap rudder cables to pedals
- needed oil to achieve pressure
- did w&b
- found tailwheel wobble
- rudder pedals not strong enough


 
Apr 23, 2023     Installed seat belts - (6 hours)       Category: Interior Finish
What a PIA but after cutting extra access hole in center console installed and bolted in all seat belt fittings
Ken bent outboard connectors for me
I cut them down and drilled smaller 1/4 hole to fit existing attachment points


 
Apr 23, 2023     Programmed EFIS values - (1 hour) Category: Instrument Panel
 
Apr 16, 2023     Changed valve to fix tire leak - (2 hours) Category: Landing Gear
With Chris help, changed tube valve, now holds pressure and installed Fobo BT sensors
 
Apr 15, 2023     Bled brake lines - (4 hours) Category: Controls
Needed to bleed lines 3 times
Bubbles after first time
Needed to bleed top screw on calipers as well
 
Apr 14, 2023     Finished wiring for AP & ELT - (8 hours)       Category: Instrument Panel
Connected reflexor to power & stick
Connected roll servo to fwd plugs
Connected aileron servo to fwd plugs


 
Apr 18, 2023     Made bracket & Installed pitch servo - (8 hours)       Category: Avionics
Made servo bracket out of G-10
Sanded inside under header tank
Floxed & BID in bracket
Installed servo


 
Apr 18, 2023     Finished rudder/tailwheel cables - (8 hours)       Category: Controls
After bellcrank and swaging, all fittings on inside were hand crimped ... What a PIA in the tail cone to crimp but its done
This includes installation of bungees to spring rudder pedals fwd


 
Apr 16, 2023     Installed aileron servo bracket - (4 hours)       Category: Controls
Made G10 plate from metal bracket as template
Floxed abd double BID on both sides


 
Apr 15, 2023     Designed canopy locking mechanism in OnShape - (2 hours)       Category: Fuselage
Took drawings from plans and converted into OnShape CAD ... https://cad.onshape.com/documents/6fe5f2054c0e0da1003c819e/w/532922969c01a880328d39e8/e/0591008fdf0827bafab3f3cf
Ordered parts from xometry.com


 
Apr 12, 2023     Installed 3 antennas - (4 hours)       Category: Avionics
Installed new special fiberglass antennas that won't need a metal ground for VHF, ELT and transponder. In picture see the ELT antenna, the transponder antenna is mounted on the left just outside picture and the VHF antenna is the luggage compartment


 
Apr 16, 2023     Installed all tail aft rudder/tailwheel cables - (16 hours)       Category: Controls
Swaged fittings outside by Ballenger Spars
Ran wires and nylon covers inside tail
Crimped wires to rudder
Crimped wires to tailwheel
Shrink tubed endings
Connected and tightened to bellcrank


 
Apr 12, 2023     Resin wiped lower cowling - (1 hour)       Category: Engine
Per Jason Skiby, resin wiped lower cowling for better cleaning


 
Mar 16, 2023     Tidied Up Engine Lines & Wires - (4 hours) Category: Engine
Went around engine and tidied up all lines, wires and put them in place with zip ties and clamps
 
Mar 19, 2023     Torqued & Safety Wired Engine - (4 hours) Category: Engine
With Kevin's help, went around engine, torqued all bolts and nuts and safety wired everything including prop
NO ACCESS to oil pressure nut, next time when engine off!!!
 
Mar 25, 2023     Torqued Spark Plugs - (1 hour) Category: Engine
 
Mar 28, 2023     Mounted oil hatch - (4 hours)       Category: Engine
Riveted in piano hinge for hatch
Drilled holes for SkyBolts
Riveted in SkyBolts for locking hatch


 
Mar 27, 2023     Installed brake calipers & Bled lines - (8 hours)       Category: Landing Gear
Had Ken true my wheel to brake disk mount
Adjusted brake caliper mounts for more space for brake lines
Installed wheels & loosly brake calipers
Cut copper lines and extended with nylon lines
Bled fuel lines from calipers


 
Mar 26, 2023     Installed Canopy Hinge - (8 hours)       Category: Fuselage
Fit, drilled and mounted bottom hinge on fuselage, needed some Dremel work to make space for nuts
Fit, drilled and mounted canopy hinge with some play
Then floxed in canopy nuts and took out play ... what a PIA :-)


 
Mar 26, 2023     Installed AntiSplat kit - (4 hours)       Category: Engine
Bought kit after recommendation from Jim Patillo
Connects to engine blow and goes into exhaust


 
Mar 26, 2023     Made ELT tray - (4 hours)       Category: Avionics
Used metal try as form to create fiberglass ELT tray


 
Mar 25, 2023     Installed exhaust heat shields - (4 hours)       Category: Engine
Purchased at ACS after recommendation from Kevin & Ross for heat shielding fuel injectors
Installed them and turned around items in the way


 
Mar 23, 2023     Installed exhaust heat muff - (1 hour)       Category: Engine
Designed with ACS referred welder from Vegas
Installed onto exhaust ... Do I need a bracket to hold it?


 
Mar 22, 2023     Finished rough cowling work - (40 hours)       Category: Engine
Made injector bump
Primed outside
Fit exhaust pipes
Installed funnel for intake air
Test fit intake rings


 
Mar 12, 2023     Brake Line Install - (8 hours)       Category: Landing Gear
Installed brake fluid cylinder
Installed brake lines from cylinder to top of toe brakes
Installed brake lines from each wing to bottom of toe brakes


 
Mar 15, 2023     Completed Plenum - (8 hours)       Category: Engine
Added horizontal carbon front plate to stop air from escaping


 
Mar 11, 2023     Mounted ADC - (1 hour)       Category: Instrument Panel


 
Mar 11, 2023     Cut wheel axles - (1 hour)       Category: Empennage


 
Feb 23, 2023     Installed FlightStick - (3 hours)       Category: Avionics
Added plugs for quick connect
Found issue with PTT button that needs to be NO … change push button


 
Feb 21, 2023     Installed new FlightStick - (4 hours)       Category: Avionics


 
Feb 17, 2023     Fix avionics connection with new BT hub - (10 hours)       Category: Avionics
Had problems with USB connections to FDC
Needed new powered hub


 
Feb 19, 2023     Aligned wheel axles - (16 hours)       Category: Landing Gear
Widen inner hole
Mark 2” fwd and 3” up for positive camber and toe out following David Gall advice
Move outside hole with bore sight


 
Feb 12, 2023     Weight check - (2 hours)       Category: Inspection


 
Feb 11, 2023     Installed elevator trim - (10 hours)       Category: Controls
Bought springs & rope
Epoxied in roller
Connected everything with trim wheel


 
Feb 22, 2023     Mounted new prop - (1 hour)       Category: Propeller


 
Feb 02, 2023     First engine run … SUCCESS - (8 hours)       Category: Engine
Installed throttle bracket
Primed with oil
First engine start a little leak on oil filter bracket fixed after tightening
Watch engine crank fire leak
Alternator not charging


 
Jan 30, 2023     Pickup propeller - (8 hours)       Category: Propeller
Picked up prop at Catto, though wrong one and got replaced a few days later


 
Jan 27, 2023     Finished panel including decals - (40 hours)       Category: Avionics


 
Jan 23, 2023     Installed prop extension - (4 hours)       Category: Engine
Installed pressed fitting lugs
Drilled holes in bolt tip for magnets
Epoxied magnets into holes and measured gap
Tightened bolts to 30 lb ft


 
Jan 23, 2023     Hung engine - (8 hours)       Category: Engine
Mounted return fuel line
Mounted oil pressure line
Mounted oil pressure wiring
Hung engine with aircraft grade bolts … NOTE start tightening bottom bolts first!!!


 
Jan 22, 2023     Started panel wiring - (16 hours)       Category: Instrument Panel
Started wiring instrument panel
Mounted additional items, USB, vents, ELT remote


 
Jan 19, 2023     Installed headset plug panel - (1 hour)       Category: Instrument Panel
Cut hole in seatback
Installed recess panel


 
Jan 18, 2023     Panel anodized - (1 hour)       Category: Paint / Decals
Picked up anodized panel at Arnold Metal Finishing in SJ


 
Jan 19, 2023     Installed TXP/ RadioCom tray - (1 hour)       Category: Avionics
Mounted tray being seat back


 
Nov 26, 2022     Finished wiring in front of firewall - (8 hours)       Category: Firewall
Connected last few wires, injectors etc


 
Nov 16, 2022     Fix soft spot on passenger side - (16 hours)       Category: Fuel System
Cut top open and clean
Fit in new foam
Flox in foam
Triple BID
Prime over


 
Nov 16, 2022     Made glare shield - (16 hours)       Category: Interior Finish
Cut from G10
Mounted with clicos and then flush screws
Hard work to get to fit to panel top
Made tabs


 
Nov 07, 2022     Installed fuel lines - (4 hours)       Category: Fuel System
Pickup to pump with flex
Pump to firewall with hard
Firewall to return in header with hard


 
Nov 03, 2022     Ran battery / starter wires - (2 hours) Category: Avionics
Drilled holes in firewall & bulkheads
Ran starter + (White)
Ran main bus + (Red)
Ran ground - (Black)
Fit in fuel feed line
 
Nov 02, 2022     Installed rudder pedals & toe brakes - (4 hours)       Category: Controls
Installed floor mounts
Installed brake cylinders
Installed pedals

... pedals need a little adjustment, longer I believe ...


 
Nov 03, 2022     Glued in zip tie holders - (1 hour) Category: Avionics
Glued in zip tie holders all around interior
 
Nov 03, 2022     Installed various SDS EFI parts - (4 hours) Category: Engine
Injectors
Fuel rail fittings
Injector fuel fittings
Injector plugs/wires
Hall sensor bracket
Hall sensor ... needs tightening
 
Nov 01, 2022     Painted interior with bilge paint - (8 hours)       Category: Paint / Decals
Two coats of white epoxy primer Petit)
One coat of light grey epoxy bilge paint ( Total Boar)


 
Oct 29, 2022     Primed interior and luggage compartment - (8 hours)       Category: Paint / Decals
Primed forward fuselage with 2 part epoxy white, two coats, including luggage compartment


 
Oct 29, 2022     Added finger holes - (2 hours)       Category: Instrument Panel
Cut half holes into ipad holders and panel


 
Oct 14, 2022     Installed bottom tap - (1 hour)       Category: Fuel System
Had to use a step because turns out fitting is smaller than ACS said, might get a larger one eventually


 
Oct 16, 2022     Fixed bolts for throttle body - (3 hours)       Category: Engine
Removed old studs
Replaced with new allen bolts


 
Oct 21, 2022     Installed Trim Wheel & Test Fit Panel - (8 hours)       Category: Controls
Installed trim wheel with tapped phenolics
Cut slot into panel and mounted with wheel


 
Oct 25, 2022     Installed rudder & break mounts - (40 hours)       Category: Controls
Did lots of planning and deciding
Opted for Delrin rudder pedals mounts, designed in OnShape, water jetted by Eric
Decided to use phenolic to mount with bolts counter sunk and floxed and double BID to floor
Used aluminum to create break cylinder mounts, mounted with special bolts floxed and double BID to floor


 
Oct 26, 2022     Painted rudder pedals - (2 hours)       Category: Paint / Decals
Used Rustoleum primer and Industrial Enamel to paint pedals


 
Oct 28, 2022     Primed interior - (4 hours)       Category: Paint / Decals
Used Petitt White Epoxy 2 part Primer
Painted luggage compartment
Painted outside spots
Painted fuel tank repair
Painter interior area and foot well


 
Oct 15, 2022     Installed arm rest hinge - (2 hours)       Category: Interior Finish


 
Oct 27, 2022     Installed firewall fwd comments - (4 hours)       Category: Firewall
Installed various engine compartment items on firewall


 
Oct 06, 2022     Test fit panel & rudder placement - (8 hours)       Category: Instrument Panel
Test cut rudder pedal mounts ... need mods, redoing in Delrin
Test cut panel, first top, then all of it but without instruments


 
Oct 02, 2022     Added bell crank in tail - (4 hours)       Category: Controls
Made phenolic base
Floxed phenolic in place
Added 2 layers of BID
Sat bellcrank on it temporarily


 
Oct 01, 2022     Applied 2 extra layers of BID in tail - (4 hours)       Category: Fuselage
Added 2 layers of BID in tail for structural support, per Jim P and Jason S


 
Sep 29, 2022     Closing main fuel tank - (40 hours)       Category: Fuel System
Drill 1 1/2 hole for main tank fill
Bend 1 1/2 PVC pipe to fit
Flox in PVC from header to main
Drill fuel pickup from main
Bend to fit and flox fuel pickup line
Sand & prep border surfaces
Flox in inside skin
Slurry foam
Glue in foam with flox
Slurry outside of foam ... after once forgetting and having to redo :-)
Apply 3 layers of BID on outside
Apply micro & sand ... 3 times to get nice and flat
Flip plane over on its wheels


 
Sep 18, 2022     Weight fuselage - (1 hour)       Category: Inspection
Added all fuselage parts and weight it ... Total 391 without engine


 
Sep 18, 2022     Closed off firewall with boxes - (6 hours)       Category: Firewall
Finished firewall boxes
Glued them in with 10 min epoxy
Applied thick layer of flox on cockpit side
Applied 2 layers of BID on firewall side


 
Sep 18, 2022     Fiberglassed in header fitting - (3 hours)       Category: Fuel System
Cut aluminum piece
Fiberglassed into header tank
Cut fill hole into fiberglass tank


 
Jun 28, 2022     Made firewall box - (3 hours)       Category: Firewall
Cut out of ply and foam box
Fiberglassed outside


 
Jul 28, 2022     Molded new bottom main tank skin, inside fuselage - (4 hours)       Category: Fuel System
Borrowed fuselage from Stan
Laid down 3 layers of BID plus peel ply on duct tape


 
Jul 27, 2022     Cut out old fuel filler box & pipe - (2 hours)       Category: Fuel System
Cut out box from outside
Cut off lid and grind down piano hinge
Epoxied door back into place with 1 BID in back ... fixed air bubbles in peel ply after taking picture :-)


 
Jul 26, 2022     Cut bottom open for future work - (2 hours)       Category: Fuselage
After talking with Jason, decided to cut bottom open


 
Jul 23, 2022     Designed new fuel system - (4 hours)       Category: Fuel System
Looked at what's needed for fuel injection
Realized I didn't need a gravity fed header tank feed
Redesigned it with fuel coming out of main tank
Discussed with various folks
Decided to eliminate facet pump and 2 extra fittings
Problem of how to fit low point outlet and fill intake by fuel tank leak / redo


 
Jul 23, 2022     Investigated warped floor under fuel tank - (8 hours)       Category: Fuselage
Found warped floor under tank
Consulted with Jason Skiby and decided to cut bottom open
Took off engine
Installed engine mount bracket
Flipped plane
Cut bottom skin
Removed fuel soaked foam
Pressure tested tank and found many pin holes in skin
Cut openings to look at fabric --> not enough wetted


 
 
Jul 14, 2022     Torqued everything according to SDS manual specs - (1 hour) Category: Engine
Spark plugs 19 ft lbs
Spark plug adapters 25 ft lbs ... per service bulletin on April 26/19 http://www.sdsefi.com/cpi.htm
1/2 bolts on engine 180 in lbs (vacuum cover, throttle body)
7/8 bolts on engine 110 in lbs (magneto covers, starter, vacuum pump cover)
 
Jul 14, 2022     Floxed in header tank donut - (2 hours)       Category: Fuel System
Couldn't bend return tube, made a wooden piece to press the donut in
Applied epoxy inside, then flox, then donut, then BID, then peel ply


 
Jul 14, 2022     Made bell crank - (4 hours)       Category: Controls
Designed CAD file
Riveted bearing into bellcrank


 
Jul 14, 2022     Installed more engine components - (6 hours)       Category: Engine
With new o-rings, bolted on vacuum pump cover and throttle body
Made a bracket for the fuel distribution block
Mounted fuel distribution block
Tightened 1 exhaust nut for all 4 pipes ... needs more work

!!! CAN'T TIGHTEN ONE NUT ON THROTTLE BODY !!!


 
Jul 13, 2022     Continued engine components install - (8 hours)       Category: Engine
Installed tapped intake elbows
Torqued starter, magneto cover, oil screen cover etc according to https://www.csobeech.com/files/TCM-Torque-SB96-7D.pdf
Installed intake tubes with new rubber fittings and hose clamps


 
Jul 08, 2022     Tapped fuel intakes - (2 hours)       Category: Engine
Took off and marked fuel intake elbows
Eric tapped them per SDS instructions


 
Jul 13, 2022     Repaired all aileron fairings - (4 hours)       Category: Fuselage
Left inboard aileron fairings were cracked, on both main fuselage and tail portion
Filled inside with micro, after wetting foam with epoxy
Sanded down the fairing to give more clearance to aileron avoid future cracking


 
Jul 11, 2022     Installed new aileron spacers - (4 hours)       Category: Controls
When cutting corroded aileron tubes out, spacers died with it
Ken created new spacers
Installed them after repairing fiberglass damage


 
Jul 11, 2022     Installed u-joint for ailerons - (8 hours)       Category: Controls
When installing reflexor, realized I needed a joint in aileron tube
Added phenolic in seat bulkhead, flox and BID
Added u-joint
Polished & primed tube


 
Jul 08, 2022     Installed main tank fuel sender - (4 hours)       Category: Fuel System
Cut hole with two different hole saws
Cleaned hole and sanded prep
Fluxed donut into place
Put down a layer of BID sounds outside
Cut hole for header tank ... Fuel return in the way:-(


 
Jul 08, 2022     Created arm rest opening - (4 hours)       Category: Fuselage
Cut hole
Removed t tail mechanism
One layer of BID on backside
Filled gaps with micro


 
Jun 27, 2022     Installed oil screen cover - (1 hour)       Category: Engine
Bolted down oil screen block cover
Insalled oil temp sensor


 
Jun 27, 2022     Made & Installed Reflexor - (16 hours)       Category: Controls
Made reflexor parts in CAD
Epoxied reflexor donut into space, after cutting first too high
Cut aileron torque tube to allow for clearance ... need union joint
Installed all connecting rods


 
Jun 27, 2022     Cleaned and installed all control surfaces - (8 hours)       Category: Controls
Installed rudder ... Slight up and down slop, maybe a longer spacer
Installed elevators ... Just temporarily, with out counter weights, waiting till inside painted
Installed ailerons ... Drilled new holes, cleaned all control arms, waiting for universal joint union and need shorter bolts on bottom of arms, spacers need to be cut too


 
Jun 25, 2022     Test fit reflexor - (4 hours)       Category: Controls
Sanded parts to fit
Cut wrong hole location and reglazed
Test fit assembly


 
Jun 25, 2022     Installed control surfaces - (4 hours)       Category: Controls
Cleaned all controls from rust
Test installed all surfaces


 
Jun 25, 2022     Assembled rudder pedals - (3 hours)       Category: Fuselage
Cleaned pedals, removed all rust
Assembled parts
Primed with Zinc
Test fit length


 
Jun 25, 2022     Primed interior - (8 hours)       Category: Fuselage
Sanded, cleaned and then primed interior areas, including foot well and luggage compartments


 
Jun 21, 2022     Removed t-tail bumps - (8 hours)       Category: Empennage
Cut off & sanded flusgh phenolic holes
Faired holes on both sides


 
Jun 22, 2022     Installed new oil filter adapter - (1 hour)       Category: Engine
New adapter installed
Bottom screw not tightened


 
Jun 21, 2022     Cleaned, sanded & primed inside cockpit       Category: Fuselage
Cleaned & sanded inside cockpit
Primed with West Marine Petite Epoxy Primer
Need to finish baggage compartment & footwell


 
Jun 19, 2022     Installed engine mounts - (8 hours)       Category: Firewall
Fluxed in G10 as backing plates
Sanded front flush
Drilled center holes and held with temp bolt from HD
Drilled and bolted down around outside with 3-4 bolts


 
Jun 17, 2022     Installed REAL pushrod tubes - (5 hours)       Category: Engine
Installed half of them with Kevins help
The rest installed on my own ... need to keep an eye out for leaks


 
Jun 15, 2022     Removed rudder pedals & tabs - (3 hours)       Category: Engine
Removed a few myself, but also got help from Joe, such a nice kid


 
Jun 15, 2022     Removed oil screen housing - (1 hour)       Category: Engine
Turns out oil screen housing interferes with firewall
Removed housing, need a block off plate


 
Jun 16, 2022     Test fitted engine mounts - (4 hours)       Category: Fuselage
Hung engine in front of engine, needed alternator hole
Hung engine again, needed more clearance on all holes
Location of engine mounts was perfect


 
Jun 17, 2022     Trimmed firewall more - (2 hours)       Category: Fuselage
Needed extra hole for alternator
Needed more clearance for starter


 
Jun 17, 2022     Made baggage hole covers - (4 hours)       Category: Fuselage
2 BIDs each side
Foam inbetween
Trimmed to fit


 
Jun 14, 2022     Drilled engine mount center holes - (3 hours)       Category: Firewall
Printed firewall template @ Fedex to scale
Mounted paper template & checked leves
Drilled center holes for new engine mounts


 
Jun 14, 2022     Mounted alternator gear assembly - (1 hour)       Category: Engine
Installed gear assembly ... COTTER PIN NEEDS TO BE CHECKED


 
Jun 14, 2022     Microed canopy seam - (1 hour)       Category: Fuselage
Applied micro over foam seam on canopy


 
Jun 14, 2022     Installed baggage tray lip - (3 hours)       Category: Fuselage
5min epoxied in lip from foam
Applied micro on front and behind to make round
Applied BID all around


 
Jun 13, 2022     Remounted tail section - (2 hours)       Category: Fuselage
Removed old screws
Cleaned & sanded seam
Installed new washers & screws


 
Jun 12, 2022     Mounted new tailwheel - (3 hours)       Category: Landing Gear
Sanded down tailwheel spring
Floxed in new tailwheel attachment
Drilled hole & bolted together
Tested with a bounce per video ... redo with passengers inside


 
Jun 12, 2022     Cut brake opening - (3 hours)       Category: Landing Gear
Took off old brakes
Disassembled & cleaned used brakes
Cut bigger holes in wheel pants for new floating brake mechanism


 
Jun 12, 2022     Installed tires - (3 hours)       Category: Landing Gear
Removed old tires
Checked tubes
Fixed valve
Reinstalled with new tires


 
Jun 11, 2022     Installed 2 of 4 new pushrod tubes - (4 hours)       Category: Engine
Removed old pushrod tubes
Installed new REAL pushrod tubes
Removed intake tubes & cleaned them ... not ready install until injectors arrive and are installed


 
Jun 06, 2022     Fiberglass Day - (10 hours)       Category: Fuselage
Cut off tail tbar attachment
Cut & fiberglassed baggage tray hole
Cut canopy backwall
Made left arm rest fiberglass cover
Cut starter hole in firewall
Floxed shut old holes

... all with the help of Jason Skirby, Mr Fiberglass Jr


 
May 08, 2022     Removed elevator & rudder controls - (4 hours)       Category: Controls
Disconnected & removed aileron tubes (not corroded, can be reused)
Disconnected & removed rudder pedals (need to take the tabs out because pedals are too far back)

Had fun doing this with the help of a new friend from the FB event


 
May 08, 2022     Removed corroded ailerons - (4 hours)       Category: Controls
Cut off corroded tubing
Disassembled aileron mechanism ... needs to be revised for reflexor anyhow
Drilled out corroded tubes (Ken did it, what a hero)


 
May 03, 2022     Moved plane inside - (3 hours)       Category: Workshop
Took plane apart
Took off tail
Cleaned inside
Removed Revmaster engine
Moved plane into hangar


 


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