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Project: nburkholder -
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Categories

Show All Entries - (322)
Research
Workshop - (5)
Empennage - (49)
Fuselage - (125)
Firewall - (10)
Tail Feathers
Wings - (29)
Controls - (1)
Avionics - (25)
Lighting - (2)
Instrument Panel - (8)
Landing Gear - (8)
Engine - (34)
Propeller - (2)
Fuel System
Interior Finish
Paint / Decals
Inspection - (1)
Tools
Wiring - (23)


Builder Name:	Nancy Burkholder -

Project:	Vans - RV-9 - VIEW REPORTS
Total Hours:	1151.6
Total Flight Time:
Total Expense:	$2.00
Start/Last Date:	May 14, 2022 - No Finish Date

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

Home or Last Project Picture

Apr 28, 2024 Add Filter Air Box Baffle - (1.5 hours)

Category: Engine

Add silicone rubber baffling to the filter air box snorkel to lower cowl air inlet.

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Apr 28, 2024 Move Oil Cooler Right 3/4" - (2 hours)

Category: Engine

Need to move the firewall mounted oil cooler left 5/8" to increase spacing with the mechanical fuel pump exit port. Fabricate a new and longer aluminum angle that mounts to the firewall to support the oil cooler aft mount tabs. This is a tedious location for mounting because the engine mount hinders access to the attaching hardware. Ultimately persevered and the cooler is hopefully mounted with sufficient clearance with the fuel pump. Right picture shows before moving and the left picture after moving oil cooler.

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Apr 28, 2024 Fasten Aluminum Backing Tabs to Front Lower Cowl - (1 hour)

Category: Fuselage

Match drill the front top and bottom cowl behind the propeller spinner for three screws on the left and right sides. Remove the top cowl and fabricate aluminum tabs to reinforce where nutplates will be mounted for the screws. Epoxy the tabs to left and right side. Remove the lower cowl and set aside to allow the epoxy to cure.

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Apr 27, 2024 Lower Cowl Skybolts and Rivets - (4 hours)

Category: Fuselage

Remove upper and lower cowl. Using a pneumatic riveter with a very narrow jaw. finish riveting the horizontal cowl lower attach plates for rivets that could not be reached with a stock riveter due to the close clearance between the firewall attach point and the engine mount. Rivet Skybolt receptacles to the flanges on the lower cowl at the vertical firewall joint on the right and left sides. Drill the cowl for grommets, attach grommets, and insert studs. Fit cowl lower and upper cowl. Adjust stud depth for a few studs that were not set for the correct depth. Note the clearance between the lower cowl and the filter air box snorkel. I believe this location is ready for installation of rubber baffling.

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Apr 24, 2024 Mount Skybolts at Right Cowl Horizontal Split Line - (2.5 hours)

Category: Fuselage

Rivet flanges to lower cowl. Rivet receptacles to flanges. Mark Skybolt hole locations on upper cowl, drill, and attach grommets and studs. Verify cowl fit and adjust several Skybolts for correct depth.

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Apr 23, 2024 Prepare Skybolt Flanges for Right Cowl Split LIne - (3 hours)

Category: Fuselage

Mount Skybolt flanges to the lower cowl at the right horizontal split line. Match drill the flanges to the cowl. Deburr, machine countersink, and prime the flanges. Machine countersink the lower cowl.

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Apr 21, 2024 Attach Skybolt Flanges to Lower Cowl Horizontal Split LIne - (3 hours)

Category: Fuselage

Rivet Skybolt flanges to left side of lower cowl at the horizontal split line. Match drill the upper cowl to the Skybolt flanges. Drill upper cowl to accept grommets. Install studs and attach the upper and lower cowl along the left horizontal split line and along the firewall. Pull pins on the receptacles to lock the receptacles in place.

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Apr 20, 2024 Prepare Skybolts Along Left Horizontal Cowl Split Line - (3 hours)

Category: Fuselage

Mount flanges to the lower cowl along the horizontal split line. Match drill the attaching rivets using a rivet fan. Deburr, machine countersink, and prime flanges. Machine countersink the lower cowl.

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Apr 20, 2024 Install Skybolts on Upper Cowl at Firewall - (2 hours)

Category: Fuselage

Drill remaining upper cowl at firewall to accept grommets.

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Apr 19, 2024 Trim Lower Cowl Horizontal Split LIne - (3 hours)

Category: Fuselage

Trim lower cowl horizontal split line. The left horizontal split line has sufficient clearance with the upper cowl. The right horizontal split line needs some additional trimming towards the aft and at the nose.

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Apr 18, 2024 Trim Upper Cowl and Install Skybolt - (3 hours)

Category: Fuselage

Install 5 Skybolt receptacles and grommets. Trim the upper cowl horizontal split line.

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Apr 15, 2024 Upper Cowl Oil Door - (2 hours)

Category: Fuselage

Cut out oil door in upper cowl. Attach upper cowl to firewall fuselage with Skybolt cleco adapters. Identify trimming of the upper fuselage and verify vertical placement of the horizontal Skybolt flanges on the right side.

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Apr 14, 2024 Lower Cowl Attachment - (3 hours)

Category: Fuselage

Rivet lower cowl attachment plates to fuselage and match drill plate nuts to cowl. Not all rivets set due to not having a suitable bucking bar for close clearance with engine mount. Match drill lower cowl right vertical Skybolt cleco adapters to cowl.

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Apr 13, 2024 Lower Cowl Fuselage Attachment - (5 hours)

Category: Fuselage

Fabricate two lower cowl bottom attach plates. Apply primer and ready to rivet to fuselage. Rivet the right side lower cowl flanges to the fuselage.

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Apr 12, 2024 Fitting Cowl with Skybolts - (5 hours)

Category: Fuselage

Match drill the remaining upper cowl Skybotts to the bushings in the flanges. Fit the lower cowl and match drill the side Skybolts to the bushings mounted in the flanges.

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Apr 05, 2024 Drill Locating Holes for Cowl Skybolt Studs - (6 hours)

Category: Fuselage

Sand and apply second layer of epoxy with filler to the outside lower cowl exhaust outlet. Mount Skybolt flanges to upper cowl firewall. Tape 10 Skybolt cleco drill bushings to the flanges working from the center flange to the left and right side. Place and level upper cowl. From under the cowl shine a flashlight through each cleco drill bushing hole and mark the light spot seen on the outside of the cowl. Drill #40 and then #30 to align the cowl hole with the hole in the busing. Drill 13 of 17 upper firewall Skybolt flanges.

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Mar 30, 2024 Prime Skybolt Flanges - (3 hours)

Category: Fuselage

Scuff Skybolt flange surfaces with Scotch Brite pads, wipe with MEK cloth, and apply primer to the flanges. Apply Proseal to the left and right vertical firewall seams with the fuselage skin.

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Mar 30, 2024 Mount the exhaust hangers - (1 hour)

Category: Engine

Mount the exhaust hangers from the engine mount with Adel clamps and stainless steel hose clamps to the 4 into 1 collector.

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Mar 30, 2024 Mount Oil Cooler - (1 hour)

Category: Engine

Attach oil cooler to mounting angle on firewall and Adel clamps on the engine mount. The mount is sturdy but not easy to attach. The clearance between the oil cooler fitting and fuel pump fitting is close.

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Mar 24, 2024 Mount Lower Cowl Vertical Skybolt Flanges - (3 hours)

Category: Fuselage

Lay out the location for Skybolt fasteners on the left and right lower cowl vertical firewall attach points, clamp the flanges to the fuselage, and match drill to the vertical firewall rivet locations. Remove the flanges, deburr drilled holes, machine countersink the rivet attach holes and the Skybolt fastener holes, and remount the flanges to the vertical firewall.

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Mar 24, 2024 Supertracks Rear Mount - (2.5 hours)

Category: Fuselage

Fabricate two threaded spacers to support the aft ends of the Supertracks. Fabricate the spacers from 1/2" aluminum bar stock. Use metal lathe to cut spacers slightly long and then face off the ends flat to the desired length. Center drill the spacers and tap for 10-32 threads.

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Mar 23, 2024 Prepare Upper Cowl Skybolt Flanges - (5 hours)

Category: Fuselage

Verify fuselage level orientation. Determine approximate horizontal cowl split line. Lay out Skybolt flange locations on upper firewall. Mount and drill Skybolt flanges to the firewall upper cowl. Remove, deburr, machine countersink, and remount flanges flanges.

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Mar 22, 2024 Trim and Fit Upper and Lower Cowl - (4 hours)

Category: Fuselage

Mount lower and upper cowl and trim lower cowl to fit. Mount top cowl, mark spots that need trimming, remove cowl, trim, and remount. Repeat until the cowl fits reasonably well. Begin working through how to mount the Skybolt flanges.

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Mar 19, 2024 Mount Super Tracks, Lower Cowl - (4 hours)

Category: Fuselage

Apply second layer of fiberglass to lower engine cowl exhaust exit. Drill Super Tracks mounting holes and fabricate four shims. Fabricate tool to enable machine countersinking the forward mounting screw. Match drill the Super Tracks to the fuselage.

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Mar 17, 2024 Trim heat muff exit port - (1.5 hours)

Category: Engine

Trim about 5/8" off the right heat muff aft port due to close clearance with the #3 intake manifold. Attach scat tube to the port to verify clearance.

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Mar 17, 2024 Canopy Preparation - (6 hours)

Category: Fuselage

Clamp the sliding canopy track to the longerons and match drill the outer mounting holes. Made a decision to incorporate the Fly Boy's Super Tracks to the canopy build now. Rivet the canopy track extension to the stock track. Notch the canopy tracks at the aft top to allow the canopy rollers to exit the canopy track when sliding the canopy open. Fit the right Super Track in position and bevel the aft end to nestle next to the rear skin.

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Mar 17, 2024 Remove Cowl Pipe Mold - (.5 hour)

Category: Fuselage

Remove the mold used to form the exhaust pipe exit on the lower cowl. Trim the stray fibers and excess fiberglass at the exit.

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Mar 17, 2024 Filter Air Box Cable - (1 hour)

Category: Engine

Drill the firewall eyeball pass through to 0.186 to fit the control cable. Add a brass sleeve to the screw that attaches the control cable to the alternate air door.

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Mar 16, 2024 Fabricate Work Stand - (5 hours)

Category: Workshop

Fabricate an elevated work stand.

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Mar 16, 2024 Attach Alternate Air Door - (0.5 hour) Category: Engine

Apply RTV to the alternate air door frame and rivet frame to air box. Rivet hinge nut plate.

Mar 16, 2024 Fiberglass Cowling At Exhaust Pipe Exit - (1.5 hours)

Category: Fuselage

Create a mold from a large can wrapped with packing tape. Fit mold to lower cowling with fiber glass mat in place. Cover mat with epoxy resin.

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Mar 15, 2024 Final Cowl Trim - (4 hours)

Category: Fuselage

Trim upper and lower cowl to exact firewall clearance. The top cowling ended up with gaps that will need to be filled and shaped. The bottom cowl came out precise with only some light sanding. Cut the clearance relief for the exhaust pipe exit. The cut is ready for fiber glassing the cowling exit channel covering the exhaust pipe.

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Mar 14, 2024 Trim Cowl at Firewall - (3 hours)

Category: Fuselage

Trim upper and lower cowl at the firewall. This is an initial trim that still needs to be precisely matched to the firewall. Verify cowls are level.

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Mar 13, 2024 Canopy Cowl trim lines - (1 hour) Category: Fuselage

Mark firewall trim lines for upper and lower cowling.

Mar 13, 2024 Filter Air Box Alternate Air - (2 hours)

Category: Engine

Cut 2 11/16" hole in bottom of filter air box for alternate air door. Match drill the door frame to the air box and machine countersink the rivet holes and nut plate holes. Bend door latch to catch door. Parts ready for permanent installation.

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Mar 12, 2024 Cleco Cowling to Fuselage - (2 hours)

Category: Fuselage

Add temporary mounting flanges to firewall. Mount cowling, match drill cowling to temporary flanges, and cleco the cowling to the temporary flanges.

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Mar 12, 2024 Trial Fit Exhaust to Engine - (2 hours)

Category: Engine

Received 4 into 1 exhaust. Mount the exhaust system to the engine and verify cowl and filter air box clearances. Overall fit is acceptable except for the heat muff exit is close to the #3 intake manifold. Do not torque installation until further research how to hang rear of exhaust from engine mount and whether to apply never seize compound to slip joints and header mounting studs.

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Mar 12, 2024 Rivet Filter Air Box to Top Plate - (1 hour)

Category: Engine

Rivet the top plate to the filter air box. Mount the filter air box to the FI servo and verify the air inlet lines with the cowling air scoop.

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Mar 08, 2024 Preliminary Cowling Fit - (3 hours)

Category: Fuselage

Clamp cowling to fuselage and establish the horizontal and vertical placement using a laser level. Mount propeller spinner backplate to propeller and measure distance from propeller mounting flange to rear of spinner.

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Mar 07, 2024 Filter Air Box Fiberglass - (5 hours)

Category: Engine

Cut sides of filter air box to line with the top plate. Cleco the top plate to the air box. after applying clear packing tape to the top plate.to protect it while glassing in the cut with three layers of fiberglass mat. Over the next three days apply epoxy and mat, sand mat. After fiberglass complete paint the top plate and filter air box.

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Mar 03, 2024 Fabricate Filtered Box - (5 hours)

Category: Engine

Attach filter mounting plate to servo and clamp air box filter top plate to mount plate. Install the lower cowl and line the neck of the air box filter top plate with the cowl air scoop horizontally. Trim the neck to achieve 1/4" clearance to the cowl air scoop. Clamp the top plate to the mounting plate to prevent movement, remove both and match drill the mounting plate to the top plate. Install plate nuts and filter retainers on the top plate. Attach the mounting plate to the top plate with bolts and mount the assembly to the servo Mount the lower cowl and check the vertical alignment of the top plate with the top of the air scoop. Flute the top plate to adjust it's height to match. Remove the top plate with attached mounting plate and place the filter between the top plate and the filter air box. With clamps compress the top plate and filter air box about 1/16". The filter air box is ready to drill to the air box.

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Mar 02, 2024 More Cowl to Prop Spinner Clearance Adventures - (2 hours)

Category: Fuselage

Reviewing my prior measurement of the distance from propeller aft mounting/crankshaft flange to the spinner backing plate I mounted the plate backwards. The spinner backing plate has a 5/8" flange around the circumference for mounting nut plate attaching the spinner. This flange extends 7/16" aft from the aft backing plate mounting surface; 5/8" flange - 1/16" spinner back plate thickness - 1/16" spinner backing plate doubler). The location of the cowl relative to the crankshaft mounting is as follows. 1/4" flywheel thickness, 2" from the propeller aft mounting surface to the spinner backing plate minus 7/16" lip. Set Ez Cowl jig for 1 9/16". This distance is less than the supplied spacer that I used to set the clearance distance. Replace the spacer with the four bolts and locking nuts that hold the jig to the flange. The forward bolt head surface sets the clearance distance. The 1-1/4" bolts I have on hand are barely long enough and 1-3/4" bolts on order.

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Mar 01, 2024 Mount Aux Generator and Oil Filter - (1 hour)

Category: Engine

Mount the Monkworks generator to the vacuum pump Accessory Case. Do not torque mounting in case it needs to be removed. Attach the K&R S-15 reusable oil filter. Note location to drill safety wire attach hole. Mount the B&C crank driven alternator.

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Mar 01, 2024 Trim Lower Cowl - (2 hours)

Category: Fuselage

Trim the lower cowl to fit around gear legs.

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Feb 29, 2024 Attach Nose Bowl Plate to Cowl - (2 hours)

Category: Fuselage

Determine that the fuselage longerons leveled horizontally are the desired position for mounting the cowl. The engine crank with the attached Ez Cowl Jig is also horizontal. Horizontally center the nose bowl plate on the cowl nose bowl. Vertical center the nose bowl plate and then raise the plate about 1/8" to account for engine mount sag. Match drill and cleco the nose bowl plate to the cowl nose bowl. Place the upper and lower cowl on the Ex Cowl Jig and slide it aft until the lower cowl touches the landing gear legs.

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Feb 26, 2024 More Cowl Preparaton - (4 hours)

Category: Fuselage

Fabricate a Lexan nose bowl disk to replace the OSB disk. It's thinner and can be clecoed to the cowl. Raise the tail with a longer upright to get the longerons level. This leveled the rear longeron but upon further consideration I probably want to level the forward longeron. Added center lines to the upper and lower cowl. Modified a rubber plug inserted into the crankshaft to block moisture. The plug was initially slightly too small for a tight fit so I expanded it using a 2" socket as a mandrel and a heat gun. Then I trimmer the outer diameter to the same size as the crank OD. Attached the David Howe Ez Cowl Jig to the crank prop flange.

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Feb 24, 2024 Cowl Preparation - (3 hours)

Category: Fuselage

Complete research and order Skybolt fasteners for the cowling. Cleco the forward top fuselage skin. Add reference line 2" aft of the firewall in preparation for fitting the cowl. Pilot drill #40 the forward cowl attach screws.

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Feb 23, 2024 Fitting Engine Cowl - (3 hours)

Category: Fuselage

Grind and fit the flanges mating the upper and lower cowl at the nose bowl.

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Feb 22, 2024 Spinner Back Plate and Ez Cowl Jig - (3 hours)

Category: Propeller

Prime spinner back plate and doubler. Rivet doubler to back plate. Mount back plate to propeller hub and measure distance from the aft mounting face to the back plate. Cut out a round disc for use with the Ez Cowl jig.

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Feb 20, 2024 Cut Out Prop Spinner Backplate - (4 hours)

Category: Propeller

Match drill the propeller spinner doubler plate to the backplate. Cut out the spinner backplate to match the doubler plate.

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Feb 10, 2024 Remake Exhaust Headers - (6 hours)

Category: Engine

Not satisfied with the clearances and routing, I remade headers 1-3 to provide a more accurate model and to increase the clearance from the cowl. Create construction pictures with design notes, package up the headers for shipping to Airplane Exhaust

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Feb 08, 2024 Final Exhaust Mockup Fitting - (4 hours)

Category: Engine

Complete gluing and screwing the PVC exhaust pipe mockup. Take additional pictures to document notes and mockup details to be supplied to Airplane Exhaust.

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Feb 02, 2024 Finish Wiring and Power Up - (4 hours)

Category: Avionics

Add primary fuse block ground to firewall. Terminate CAN bus at right wing terminal strip. Add 10 ga cross tie wire from secondary fuse block to primary circuit breaker bus via a 20 amp circuit breaker. Install PFD MFD, GTX, GTR, GMA, and GMC units. Apply power and verify all units power up and CAN bus has 0 errors. Roll servo and OAT sensor mounted in right wing were not tested.

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Jan 30, 2024 Refit #2 and #4 Exhaust Primaries - (2 hours)

Category: Engine

Replace 1 1/2" PVC on #2 and #4 primaries with 1 1/4" PVC. Confer with Plane Exhaust Corp that they will replace right angle elbows with large radius turns.

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Jan 28, 2024 Mock up #1 and #3 Exhaust Primaries - (5 hours)

Category: Engine

Mock up #1 and #3 exhaust primaries using only 1 1/4" PVC pipe rather than using 1 1/2" for more complex bends.. Using one size pipe simplifies the fitting. 1 1/4" pipe has only two curved fittings: 45 and small radius 90 degree, whereas 1 1/2" has 22.5 degree and large radius 90 degree options. I plan to specify large radius for the 90 degree bends as part of the fabrication instructions. Tweak the #2 and #4 primaries layout to create more clearance between the primaries and the lower cowl.

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Jan 27, 2024 Test Fit #2 and #4 Primaries - (5 hours)

Category: Engine

Fabricate four adapters from 1 1/2" pvc pipe for fitting the primaries to collector. Test fit primaries between #2 and #4 cylinders and collector. Routing was suboptimal. I want more than 1" spacing between pipes and cowling. The efforts today were educational for how to route the pipes and notice the clearance issues.

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Jan 26, 2024 Mount Exhaust System Mockup Artifacts - (4 hours)

Category: Engine

Received a 4 into 1 exhaust mockup kit from http://www.experientalexhaust.com/. Mount four primary stub stacks to the exhaust ports. Place lower engine cowling into approximate mounting location to measure clearances from the engine to the cowling. Create temporary mount for the 4 into 1 collector supported from the engine mount.

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Jan 25, 2024 Mount Left Cable Raceway - (1 hour)

Category: Wiring

Similar to the right side cable raceway, mount a raceway on the left fuselage upright post to route wiring from the left side of the instrument panel to aft locations. Place a section of raceway along the floor to route the wiring from the post to forward of the main spar. The final location for the floor mounted raceways will be determined when installing floorboard carpets.

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Jan 23, 2024 Mount Cable Raceway - (1 hour)

Category: Wiring

Rivet cable raceway to upright post on right side of fuselage to channel wires from the instrument panel routed to aft locations. The raceway cover is removable and I've used tape to temporarily contain the wires while evaluating the overall installation. Lay in place a raceway to route wires along the floor from the support to forward of the main spar. Replace tape with raceway cover.

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Jan 20, 2024 Connect OAT sensor to AHRS - (1 hour) Category: Avionics

Connect 3 conductor shielded cable feeding the outside air temperature to the AHRS connector. Organize the wiring at the primary avionics fuse block

Jan 20, 2024 Update Secondary Battery Wiring - (4 hours)

Category: Wiring

Add #18 shielded wire to battery plus cable and attach shield to batter negative terminal. Run shielded wire to fuse block on subpanel and connect to two fuses. One fuse for the transponder keep alive and the other fuse for power to the right Lightspeed ignition. Reconnect battery shunt sense cables to fuse block. Attach Transponder keep alive lead to fuse block.

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Jan 19, 2024 Wire Avionics Bus to Airframe - (6 hours)

Category: Avionics

Attach power and ground wires from all Avionics LRUs to primary and secondary fuse blocks. Mount terminal strip to subpanel for connecting copilot PTT, panel dimmer control line, and TOGA (Connected but not used)

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Jan 14, 2024 Place Avionics Wiring Harness in Airframe - (5 hours)

Category: Avionics

Place the avionics wiring harness in the airframe and verify key connectors to the engine monitor and ADS-B receiver fit. Connect airframe CAN bus to ADHRS. Remove wiring to Lightspeed ignition to simplify wire routing. Move nut plates to better position Adel clamps that attach the harness transiting forward of the subpanel to aft. Rerun wiring from subpanel to the right fuselage floorboard and aft through the carry through spar.

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Jan 13, 2024 Complete Avionics Wiring Harness - (8 hours)

Category: Avionics

Completed creating a new wiring harness for all Garmin LRUs. Performed continuity check for power, ground, and communication busses. The harness is ready to install.

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Jan 06, 2024 Create New Wiring Harness - (6 hours)

Category: Avionics

Depin connectors to remove old wiring harness, Fabricate new wiring harness for GMC 507, GMA 245, GTR 200, and GTX 335. The new wiring harness corrects some flaws in the original wiring. All LRU wires use one common routing to move to the aft side of the subpanel. This allows the harness to be placed into the subpanel collocated with the existing wiring. The new harness allows for longer runs to the displays so that the displays have sufficient slack such that the connectors can be accessed from the front panel.

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Jan 05, 2024 Start Avionics Bus Rewire - (2 hours)

Category: Avionics

Measure LRU locations to establish approximate cable length, and topographic view depicting the cable paths. Start with GMC 507 and GMA 245 CAN bus and power. Fabricate CAN cable connection to the GMC 507.

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Jan 05, 2024 Fabricate mixture cable bushing - (2 hours)

Category: Engine

Fabricate a mixture cable bushing similar to the throttle cable bushing with a longer threaded portion for the cable.

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Jan 04, 2024 Fabricate prototype bushing - (2 hours)

Category: Engine

Fabricate from 3/4" round aluminum bar a bushing that screws on to the throttle control cable. The bushing has threads that mount the bushing to the throttle cable bracket. A similar bushing will be fabricated to mount the mixture cable.

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Dec 30, 2023 Test fit Throttle and Mixture cable attachments - (4 hours)

Category: Engine

Received clevises for mixture and throttle cables. Clock the throttle body throttle and mixture lever arms based on the cable mounting location. Both cables need additional mounting fixtures because the cable threaded ends are aft of their respective mounting brackets. The mixture cable mount needs to move left about 1" to line with the mixture lever. Fabricate bracket attached to existing mixture bracket to move attachment point 1" left. Verify throttle and mixture cables can operate their respective levers through their full range of motion. Ordered material to fabricate fixtures to mount both cables to their respective brackets. The mixture arm for the Precision Airmotive throttle body is different from the arm called out in the filter air box instructions. The good news is the new arm does not require the filter air box to be modified to correct for interference.

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Dec 29, 2023 Oil Cooler Firewall Mounting Flange - (2 hours)

Category: Engine

Drill and countersink center nutplate. Rivet left and right doublers, and three nutplates to firewall. Mount oil cooler flange to firewall.

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Dec 24, 2023 Firewall Oil Cooler Mount - (4 hours)

Category: Engine

Fabricate two doubler plates to reinforce the outside fasteners holding the aft oil cooler mounting bracket to the firewall. Drill, deburr, and dimple the firewall at the oil cooler mounting site. Will await assistance before riveting. Also need to order one K2000-3 MS21051L3 nutplate.

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Dec 22, 2023 Tentative oil cooler mount - (4 hours)

Category: Engine

Fabricate two attachment bars with nut plates. One bar will provide stabilized mounting one side of the oil cooler to the engine mount using Adel clamps. The other bar will clamp to an angle mounted to the firewall.

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Dec 21, 2023 Adjust Mixture Cable - (1.5 hours)

Category: Engine

Bend mixture cable mounting bracket to line cable with mixture control arm. Reclock mixture control arm to line up with mixture cable.

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Dec 21, 2023 Wire Starter Motor and Engine Ground - (3 hours)

Category: Wiring

Attach power cable from starting solenoid to starter motor. Add Adel clamps for support. Attach grounding strap from engine to negative battery terminal.

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Dec 19, 2023 Mount Fuil Injection Throttle Body - (3 hours)

Category: Engine

Mount fuel injection throttle body and cable mounting bracket. Temporarily place throttle and mixture cables to check for fit and alignment. The mixture cable bracket needs a slight bend to line the cable with the control arm.

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Dec 19, 2023 Remove all wiring to Garmin Avionics - (2 hours)

Category: Wiring

My original wiring did not have as much slack at the connectors that I felt was needed. Also, the CAN bus has an intermittent connection. Remove all Garmin bus wiring at instrument panel. I will rewire the avionics in the coming months.

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Dec 19, 2023 Replace starter motor - (1 hour)

Category: Engine

Replace Sky Tek starter motor with B&C starter motor.

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Dec 10, 2023 Mount engine to airframe - (3.5 hours)

Category: Engine

With assistance from Barry, remove engine from shipping crate and mount it to the airframe.

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Dec 08, 2023 Right Gear Leg Fairing - (4.5 hours)

Category: Landing Gear

Fabricate right gear leg fairing fitting hinge, drilling, countersinking, and riveting hinge halves to gear leg fairing. Test tit engine rubber shock absorbing mounts to engine mount.

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Dec 06, 2023 Complete Left Landing Gear Fairing - (3 hours)

Category: Landing Gear

Rivet one hinge half to the left landing gear fairing. Drill, countersink, and deburr the opposite hinge to the gear leg fairing. Rivet the hinge to the gear leg fairing. Fabricate a replacement left brake line.in order to fit better with fairing.

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Dec 03, 2023 Start Gear Leg Fairing Fabrication - (4 hours)

Category: Landing Gear

Trim gear leg fairing. Mount fairing to left gear leg and drill one hinge to faring. Machine countersink hinge attach rivets. Deburr hinge. Ready to set rivets.

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Nov 26, 2023 Fabricate Left Brake Line - (2 hours)

Category: Landing Gear

Fabricate and install left brake line from firewall to left caliper. Need 3/8" plastic tubing fto complete attaching brake line to gear leg.

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Nov 25, 2023 Fabricate Right Brake Line - (4 hours)

Category: Landing Gear

Fabricate right brake line from firewall to right brake caliper. Drill holes for three nut plate attach points for Adel clamps.

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Nov 24, 2023 Attach Right Brake - (1.5 hours)

Category: Landing Gear

Mount right brake and wheel pants mounting bracket to right landing gear leg.

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Nov 23, 2023 Mount Left Brake - (2 hours)

Category: Landing Gear

Attach left brake and wheel fairing mount to gear leg.

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Nov 19, 2023 Attach engine mount and landing gear - (3 hours)

Category: Landing Gear

Attach the engine mount to the fuselage. Attach the landing gear legs to the engine mount. Temporarily place tires on the axles.

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Nov 18, 2023 LRU Configuration - (2 hours)

Category: Avionics

Temporarily attach engine sensor to GEA24 engine monitor and configure GEA24 for sensors.

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Nov 09, 2023 Power up Avionics - (2 hours)

Category: Avionics

Apply power to avionics and begin test and LRU configuration task. Fix two CAN bus wiring errors. Verify transponder GPS antenna and ADS-B GPS antenna are receiving signals.

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Nov 06, 2023 Verify bus wiring - (3 hours)

Category: Wiring

Verify remaining primary and secondary avionics bus power wiring. Run CAN bus to terminal block at right wing attach location to service the roll servo. Trim wire from ELT to ELT annunciator and attach 6P4C connector to wire. Attach wire to annunciator.

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Nov 05, 2023 Verify fuse block wiring - (1 hour)

Category: Wiring

Verify avionics primary and secondary fuse block wiring.

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Nov 04, 2023 Install ADS-B and Transponder Antennas - (5 hours)

Category: Avionics

Mount ADS-B and transponder antennas. Fabricate cables to connect transponder antenna to GTX 335 and ADS-B antenna to GDL 50R. Add connector to Com antenna wire and attach to GTR 200 Com radio.

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Nov 03, 2023 Begin Wiring Checkout - (2 hours)

Category: Wiring

Verify wiring for primary master contactor, secondary master contactor, and avionics master switch. Verify primary and secondary power, and ground for both G3X displays.

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Nov 01, 2023 Fabricate and Install Antenna Cables - (4 hours)

Category: Avionics

Attach RF connectors to ELT and GPS antenna cables. Route ELT antenna cable to ELT. Route GPS antenna cable to panel mounted GTX 335 transponder.

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Oct 29, 2023 Mount Com Antenna - (1 hour)

Category: Fuselage

Mount the Com antenna. I may rivet the doubler plate to the fuselage to facilitate future maintenance.

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Oct 28, 2023 Antenna and Cable Infrastructure - (5 hours)

Category: Fuselage

Mount 5 lug terminal strip to the fuselage on the right near the right wing attach point. This strip will splice the CAN bus to the roll servo and the autopilot disconnect wire. Permanently mount the ADS-B receiver mounting brackets to the forward fuselage. Fabricate a doubler plate for mounting the COM antenna to the bottom fuselage aft of the baggage compartment.

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Oct 27, 2023 tid bits - (2 hours)

Category: Fuselage

Fabricate a bracket to hold a 5 lug terminal strip. Add zip tie mounts to fuselage to route GPS and ELT antenna cables.

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Oct 23, 2023 Add conduit - (2 hours)

Category: Fuselage

Add conduit to route GPS and Com coax cables from center fuselage on right to behind the baggage compartment bulkhead.

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Oct 22, 2023 Rivet Doubler Plates to fuselage - (2 hours)

Category: Fuselage

Dimple fuselage at GPS and ELT doubler plates. With assistance rivet doubler plates to fuselage.

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Oct 21, 2023 GPS & ELT antenna doubler plates - (5 hours)

Category: Fuselage

Fabricate GPS and ELT antenna doubler plates. Match drill fuselage for both plates.

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