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Project: nburkholder -
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Categories

Show All Entries - (334)
Research
Workshop - (5)
Empennage - (49)
Fuselage - (131)
Firewall - (10)
Tail Feathers
Wings - (32)
Controls - (1)
Avionics - (25)
Lighting - (2)
Instrument Panel - (8)
Landing Gear - (8)
Engine - (36)
Propeller - (2)
Fuel System
Interior Finish
Paint / Decals
Inspection - (2)
Tools
Wiring - (23)


Builder Name:	Nancy Burkholder -

Project:	Vans - RV-9 - VIEW REPORTS
Total Hours:	1181.4
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

May 14, 2024 More Canopy Track Attachment - (3 hours)

Category: Fuselage

Fabricate two new spacers to fit under the rear screw holding the canopy rail to the fuselage. The plans call for 1/8" thick shim but 3/16" completely fills the gap nicely. Fabricate two tools to facilitate attaching nuts and washers to the screws that hold the canopy rail to the fuselage. There is a large lip un the underside of the canopy attach stringer that obstructs access to the screw. One tool holds a nut and washer to a fixture that can be inserted into the slot and into position to engage the screw. The second tool provides an offset drive to a socket that allows the socket to engage the nut and the socket drive is offset to pass through the slot. Tried both tools on one screw and they worked acceptably.

Measured and ordered longer rivets and screws to attach the canopy rails and Supertrack rails to the F-705 builkhead assembly.

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May 13, 2024 Rivet F-705 Bullkhead Assembly to Fuselage - (2 hours) Category: Fuselage

Rivet on left fuselage at junction with F-705 Bullkhead Assembly. Some rivets not set by quickbuild: skin to longeron and longeron toF-705 Bullkhead Assembly. Countersink the canopy slide rail and match drill to fuselage at the forward attach screw. Drill some screw attachments for left and right side canopy roller tracks.

May 12, 2024 Rivet F-705 Bullkhead Assembly and Skins to Longeron - (2 hours) Category: Fuselage

Add rivets to right side fuselage at rearF-705 Bullkhead Assembly that were not set by quckbuild: longeron to skin and F-705 Bullkhead Assembly to longeron. Need to order some longer rivets to complete all missing rivets.

May 11, 2024 Replace Mixture Control Lever and Cable Mount - (3 hours)

Category: Engine

Exchanged the mixture control lever replacing a lever with an offset to one without the offset to eliminate any potential interference with the cowl. This moved the cable position inboard about 1" necessitating making a new cable attach bracket. Remove riveted on old bracket, fabricate a new bracket, and rivet bracket to engine mounted bracket. Clock the lever to enable the full range of motion from idle cutoff to full rich. Verify the cable moves freely through the range of motion.

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May 10, 2024 Vist with Technical Advisor - (1 hour) Category: Inspection

Mike Hilger came by and I showed him the progress since last August; mounted engine and landing gear, mounted 4 into 1 exhaust system, mounted oil cooler, and right wing repair.

May 10, 2024 Test Fuel Tank - (1.5 hours)

Category: Wings

Create manometer to measure air pressure in fuel tank. Attach manometer tubing to fuel tank vent. Attach tire valve insert in fuel drain port. Cover fuel cap with packing tape. Pressurize tank to about 24" water height. Detected leak in lower aft corner.

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May 05, 2024 Attach and Seal Right Wing Inboard Fuel Tank Rib - (2 hours)

Category: Wings

Apply Proseal to rivet line at inboard rib. Slide rib into place and cleco. Rivet rib to wing skins and tank baffle. Spread Proseal on wing attach angle reinforcement plate and corresponding rib site. Rivet wing attach angle and reinforcement plate. Apply proseal to fuel tank vent passthrough fitting and attach fitting to vent line. Spread Proseal around rib perimeter and perimeter of access hatch reinforcement ring. Clean Proseal from tools..

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May 04, 2024 Right Wing Inboard Rib - (10 hours)

Category: Wings

Drill out rivets in the right wing inboard fuel tank rib. Soften Proseal with MEK, cut Proseal with a utility knife, and extract rib. Clean Proseal from wing skin. Retrieve wing attach bracket and fuel vent feedthrough fitting. Trim attach angle reinforcement plate per drawing. Match drill rib and reinforcement plate to existing holes in attach angle. Cut 5 1/4" diameter hole in rib using a fly cutter. Lay out holes using the existing cover plate to establish desired orientation. Drill rib for nutplates. Machine countersink the cover plate reinforcement plate and dimple the rib Rivet the nutplates to the rib.

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May 01, 2024 Fabricate Canopy Slider Track - (2.5 hours)

Category: Fuselage

Drill the canopy track spacer for rivet and attach screws. Cut and bend the canopy track rail to fit the spacer. Match drill the rail to the spacer, machine countersink the rivet locations top and bottom, and rivet the rail to the spacer. Cleco the canopy track to the fuselage and verify fit.

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Apr 30, 2024 Bend Canopy Slide Spacer - (1 hour)

Category: Fuselage

Received RV-8 canopy slide spacer from Vans. The forward bend is not correct for the RV-9. Bend the spacer to match the RV-9 spacer using a c clamp as an mandrel.

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Apr 30, 2024 Verify Rubber Baffle Fitment at Cowl - (.3 hour)

Category: Engine

Attach lower cowl and verify placement of the rubber baffle between the filter air box snorkel and the lower cowl air inlet.

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Apr 30, 2024 Mount Nutplates to Lower Cowl - (1.5 hours)

Category: Fuselage

Mount the upper and lower cowls. Match drill 6 holes for #10 screws attaching the upper and lower cowls behind the propeller spinner. Drill and machine countersink for floating nutplates. Rivet nutplates.

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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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Oct 20, 2023 Complete Fly LEDs wiring - (2 hours)

Category: Wiring

Complete wiring to Fly LEDs controller board. Mount ELT annunciator to subpanel.

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Oct 18, 2023 Wiring at Fly LEDs Board - (2 hours)

Category: Wiring

Reattach wiring to Fly LEDs board. Attach left and right switches from Pilot control stick to terminal board connecting to the elevator trim relay. Connect elevator trim motor to trim relay. Connect delevator autopilot disconnect to left and right Pilot control stick. Connect Pilot PTT from panel to Pilot control stick PTT button.

Items to be completed:
CoPilot PTT,
roll servo autopilot disconnect,
grounds from trim relay deck and Pilot control stick to local airframe ground.

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Oct 16, 2023 Wire rerouting at Fly LED board - (2 hours)

Category: Wiring

Initial routing of wires to Fly LED control board and trim relay had room for improvement. Route wires to the Fly LED control board through forward floor ribs. Route wires to the trim relay through a separate grommet hole in the center tunnel rib at the aft end of the control board. Wires rerouted and ready for connection.

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Oct 15, 2023 Wiring cleanup - (3 hours)

Category: Wiring

Replace in-line fuse for primary Lightspeed Ignition with fuse block mounted to firewall. Reroute wire bundle to firewall passthrough and add Adel clamps to stabilize run. Add Adel clamp to sensor wires routed out from the firewall passthrough.

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Oct 14, 2023 Mount Terminal Blocks - (3 hours)

Category: Wiring

Mount terminal block to subpanel to terminate wires from the ELT, power, and GPS input from GDU. Mount terminal block to firewall to terminate wires from the EMS for fuel flow and oil temperature sensors.

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Oct 13, 2023 Rivet subpanel and instrument panel - (4 hours)

Category: Fuselage

Complete riveting the instrument panel and subpanel to the fuselage.

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Oct 10, 2023 Elevator Trim Circuit Breaker - (1 hour)

Category: Wiring

Install 1A pull able circuit breaker for elevator trim. Run power from circuit breaker to the floor where the trim relay is mounted.

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Oct 09, 2023 Rivet Firewall Recess to Firewall - (1.5 hours)

Category: Firewall

Rivet Firewall Recess to Firewall

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Oct 07, 2023 Mount ANL fuse block - (2 hours)

Category: Firewall

Mount the 60A ANL fuse block to the firewall. Fabricate and install #4 wire between the fuse block and master solenoid.

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Oct 01, 2023 Move pilot stick switch wiring - (1 hour)

Category: Controls

Move the wire bundle from the pilot stick switch to exit from the side of the stick above the pivot rather than exit at the bottom. Route the wire bundle through the floor rib to the bay holding the trim relay.

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Oct 01, 2023 Rivet subpanels - (2 hours)

Category: Fuselage

Continue riveting forward fuselage subpanels.

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Sep 30, 2023 Mount manifold and terminal block - (4 hours)

Category: Firewall

Move sensor manifold on firewall to align with center rib for added stiffness. Mount terminal block to firewall. Terminate sensor wiring from EMS at terminal block.

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Sep 26, 2023 Complete installing AHRS doubler plate - (2 hours)

Category: Fuselage

Install nut plates and rivet AHRS doubler mounting plate to subpanel

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Sep 24, 2023 Fuselage Modifications - (8 hours)

Category: Fuselage

Move left and right wing wiring terminal blocks to inside of rib to allow full access to the outer bay when installing wing attachment bolts. Make doubler plate to attach ADHARS to subpanel. This location facilitates the display screen removal. Move sensor manifold attachment to firewall to a vertical alignment in line with center forward fuselage rib. This location is structurally stronger. Add terminal block to splice sensor wires to the leads from the GEA 24 EMS.

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Sep 22, 2023 More wiring - (4 hours) Category: Wiring

Wire B&C primary power voltage regulator sense wire to main fuse block and pitot heat power from panel circuit breaker to terminal block near fuselage left wing. Wire Fly LEDs controller board for left wing (position lights, wing strobes, and landing lights) to terminal block near fuselage left wing. Wire strobe, landing light power from panel, and wig wag signal from panel to controller board.

Sep 21, 2023 More Wiring - (4 hours)

Category: Wiring

Mount secondary power shunt to subpanel and splice in series with power from secondary battery. Add shunt sensor wiring and fuse blocks. Connect primary and secondary shut sensors, Light Speed tach signals, and wiring for fuel flow, fuel pressure, oil pressure, oil temperature, and manifold pressure to GEA 24 engine monitor. Mount sensor manifold to firewall.

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Sep 17, 2023 Subpanel wiring - (4 hours)

Category: Wiring

Wire both Lightspeed "P-leads" to the keyed ignition switch. Mount the B&C voltage regulator to the subpanel and wire supply pins to the primary master field switch field and then to the primary fuse block.

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Sep 16, 2023 Subpanel fabrication and current shunt - (6 hours)

Category: Fuselage

Begin riveting the forward fuselage subpanel. Add nutplates for mounting the primary fuse block. Fabricate bracket to hold the primary power shunt and sensor wire fuse blocks.

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Sep 10, 2023 Fabricate terminal strip mount - (6 hours)

Category: Wiring

Fabricate mounting for two 10 position barrier terminal strips, mounted near the main spar on the left and right sides. Wire the position and strobe light wires from the Fly LEDSs controller to the right wing barrier strip. Wire the power leads to the left Lightspeed module to the front panel circuit breaker.

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Sep 08, 2023 LIghtspeed ignition wiring - (4 hours)

Category: Wiring

Mount pre-made cable attaching power and the mini crank sensor to both Lightspeed ignition modules. The sensor connectors fit through the firewall penetrations without the back shells. Shield the sensors on the engine side of firewall with bubble wrap for protection until ready to mount to engine. Attach elevator trim tab position wires and two fuel level sensor wires to the GEA 24 engine monitor.

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Sep 03, 2023 GPS keep alive fuse - (1 hour)

Category: Wiring

Mount a single fuse block from the secondary battery for GTX 335 GPS keep alive pin.

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Sep 02, 2023 More Panel Wiring - (3 hours)

Category: Instrument Panel

Wire the copilot mic and headphone jacks. Wire the auxiliary power socket. Wire the USB power socket.

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Sep 01, 2023 Primary Power to panel - (2 hours)

Category: Instrument Panel

Replace the dual split bus bar connecting circuit breaker switches on front panel with a one piece bus bar. Wire bus bar to primary power distribution header. Wire pilot side microphone and headphone panel jacks.

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Aug 31, 2023 Lighting and Panel power - (2 hours)

Category: Instrument Panel

Fabricate two copper bus bars to connect panel circuit breaker switches. Connect strobe, landing, and position light wiring to corresponding panel circuit breaker switches. Connect wig-wag wire to panel mounted switch.

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Aug 29, 2023 Flap & ELT Power - (3 hours)

Category: Wiring

Connect ELT to main bus fuse block. Run wire from flap motor location forward and up to the flap switch on the instrument panel. Wire flap switch to allow reversing the flap motor direction. Connect flap power to main fuse block. Add nutplates to subpanel to attach two Adel clamps for holding wire coming up from the floor along the fuel vent lines on the left and right side.

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Aug 27, 2023 Instrument Panel attachment bracket - (1.5 hours)

Category: Instrument Panel

Fabricate a mounting tab that attaches to the instrument panel right side to the right fuselage attachment bracket. The tab fastens the instrument panel lower lip to the right fuselage bracket. I cut the panel to facilitate installation. The mounting tab uses 2 #8 screws and nutplates to fasten the panel lip to the fuselage.

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Aug 27, 2023 Wire Copilot Display and Remote GPS/ADS-B - (5 hours)

Category: Avionics

Wire the copilot display and GDL 50R remote GPS/ADS-B receiver.

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Aug 25, 2023 Wire EMS Power/Communication Cable - (3 hours)

Category: Avionics

Wire the GEA 24 Connector providing power, CAN, and engine data to copilot display.

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Aug 14, 2023 Wire avionics power - (4 hours)

Category: Avionics

Mount primary bus fuse block to fuselage with power routed from the load side of the primary battery contactor. Wire avionics boxes power 1, power 2, and ground to avionics primary and secondary fuse blocks.

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Aug 13, 2023 Primary Bus Wiring - (8 hours)

Category: Wiring

Wire system power from load side of master contactor to 4 post terminal block. Connect avionics master relay to terminal block. Fabricate mounting bracket for primary power fuse block. Install nut plates in fuselage stringer for attachment. Update schematic and fuse block and switch list to correlate with latest design.

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Aug 13, 2023 Power wiring - (8 hours)

Category: Wiring

For both Lightspeed ignition power wiring, connect the braid directly to the corresponding primary and secondary batteries. Add a wire to the secondary battery Lightspeed power to supply power for GTX 335 keep alive. Fabricate a bracket and install a relay to control power to the avionics primary bus controlled by a panel mounted avionics master switch. Fabricate a bracket to hold a 4 terminal bus connection that will distribute power from the primary battery to the avionics primary bus and the primary power bus (anything not connected to primary or secondary avionics bus).

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Aug 07, 2023 Tech Advisor visit - (1 hour) Category: Inspection

Mike Hilger, technical advisor, inspected my construction for the first time. Mike approved of my work to date and answered all of my questions. Thank you, Mike, for sharing your experience and perspective. I can proceed with confidence knowing that my construction efforts are not deficient.

Aug 07, 2023 wing tip lens - (2 hours)

Category: Wings

Trim wing tip lens, add two nut plates to wing tip, attach lens to tip.

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Aug 06, 2023 Right wing tip lights - (6 hours)

Category: Wings

Mount right wing tip to wing. Cut out wing tip to fit "The Works" FlyLED circuit boards. Install nut plates to fasten both circuit boards to wing tip.

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Aug 05, 2023 A few wires - (1 hour)

Category: Firewall

Attach master solenoid coil wire and primary bus power to cockpit. File the split rocker switch opening to 1.25" tall.

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Aug 04, 2023 Primary Battery grounding strp - (.5 hour)

Category: Firewall

Attach ring terminal to grounding strap and attach strap to firewall and primary battery

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Aug 04, 2023 Wing Inspection Panel Nut Plates - (1 hour)

Category: Wings

Dimple two right wing inspection panels in lower wing skin. Dimple for #8 screws, dimple and rivet nutplates.

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Jul 31, 2023 Attach nut plates to right wing tip - (8 hours)

Category: Empennage

Drill, machine countersink, and rivet W-931 rib to wing tip. Attach 4-40 plate nuts to wing tip.

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Jul 29, 2023 Right wing tip - (4 hours)

Category: Empennage

Attach right aileron to wing and affix in the neutral position with the W-903 adjustment fixture. Fit right wing tip to wing and align with the aileron. Match drill the wing tip to the wing skin. Insert the W-916 tip rib into the tip and drill for rivets. Machine countersink tip rivet holes and rivet the rib tip. Insert the W-931 rib tip in place and adjust to fit the tip. Mark the rib location and bond the rib in place with thickened epoxy.

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Jul 28, 2023 Empennage intersection fairing - (4 hours)

Category: Empennage

Trim the empennage intersection fairing. Place the fairing on the fuselage and match drill through the fairing to the existing holes in the vertical and horizontal stabilizer and the fuselage.

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Jul 27, 2023 Add aircraft ground - (2 hours)

Category: Firewall

Create battery ground to aircraft frame on firewall for primary and secondary batteries. Need to install a ring terminal on the ground braid to the primary battery.

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Jul 22, 2023 primary bus avionics fuse block - (2 hours)

Category: Instrument Panel

Fabricate mounting plate identical to secondary fuse block mounting plate to hold primary avionics bus fuse block. Mount fuse block to left side of subpanel.

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Jul 21, 2023 secondary avionics bus fuse block - (3 hours)

Category: Instrument Panel

Fabricate a mounting plate for the secondary avionics bus fuse block. Mount fuse block and secondary bus master relay. Mount plate to right side of subpanel.

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Jul 19, 2023 Fitting canopy frame - (8 hours) Category: Fuselage

Starting on July 15, worked several hours per day reading the instructions for fitting the canopy side frames to the longerons and fitting the frame. Completed fitting today. Checked rear bow fit with aft turtledeck skin with the bow below the skin by 1/8 to 5/8". Checked front bow with roll bar. Front bow 1/4 to 3/4" higher than roll bar. Will consider trimming the front bows where the rollers attach after fitting the canopy bubble.

Jul 14, 2023 Fit sliding canopy frame to fuselage - (8 hours)

Category: Fuselage

Cut and drill canopy slide rails. Fabricate center canopy guide. Temporarily mount slide rails and canopy guide to fuselage and begin fitting the canopy sliding frame.

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Jul 09, 2023 Attach Roll Bar - (8 hours)

Category: Fuselage

Fabricate attachment shims, lay out roll bar attach points. Drill fuselage roll bar attach points and bolt roll bar to fuselage. Trim roll bar brace, match drill, and bolt brace to roll bar and fuselage.

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Jul 09, 2023 Add penetrations for cabling and vacuum line - (4 hours)

Category: Firewall

Add firewall penetrations for vacuum line, sensor wiring, LIghspeed Ignition trigger wires, and cockpit power.

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Jul 07, 2023 Add subpanel supports for avionics and control cables - (4 hours)

Category: Fuselage

Created subpanel supports for the avionics stack and control cables. The control cables will be attached with Adel clamps.

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Jul 02, 2023 Attach stick grips - (2 hours)

Category: Fuselage

Attach pilot and copilot stick grips to control sticks. Trim both sticks to eliminate interference with instrument panel controls.

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Jul 01, 2023 Test fit panel - (4 hours)

Category: Fuselage

Cleco upper deck spars and subpanels,and mount panel in fuselage to test fit wiring with cutout hole in subpanel. Organize wiring routed from aft into two bundles that will route to the panel along the floor to the forward uprights, one on the left and the other on the right

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Jun 30, 2023 Avionics Wiring - (4 hours)

Category: Avionics

Wire the GSU 25C and Pilot GDU 460 connectors and attach backshells.

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Jun 29, 2023 Left Wing Tip plate nuts - (2 hours)

Category: Wings

Mount 4-40 plate nuts to left wing tip. Machine countersink left wing tip skin. The flat head screws are slightly above the skin. May countersink deeper at a future time.

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Jun 25, 2023 Transponder Backshell - (3 hours)

Category: Avionics

Assemble and install GTX 335 Transponder connector backshell.

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Jun 24, 2023 Complete backshells - (3 hours)

Category: Avionics

Complete connector back shells for GMA 245 Audio Panel and GTR 200 Comm Radio.

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Jun 20, 2023 Wing Inspection Covers - (3 hours)

Category: Wings

Drill, dimple, and prime 4 wing inspection covers. Attach nut plates to two left wing inspection cover locations.

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Jun 18, 2023 Complete left wing lens cap

Category: Lighting

Trimmed left wing lens cover to fit recessed lip on wing tip. Install two nut plates to mount lens to wing.

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Jun 09, 2023 Start mounting left wing tip lights - (3 hours)

Category: Lighting

Prepare left wing tip for FlyLEDs "The Works" kit including landing lights, position light, and strobe lights. Cut left wing tip to fit printed circuit boards. Drill PCB mounting holes to position nut plates. Trim PCB to fit wing tip contour. Cut wing tip lens half in two.

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Jun 07, 2023 Audio Panel wiring - (2 hours)

Category: Avionics

Wire #2 connector except for copilot PTT wire (need to buy).

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Jun 07, 2023 Rivet wing tip stiffener rib - (1 hour)

Category: Wings

Drill, countersink wing tip, and rivet stiffening rib to wing tip.

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Jun 05, 2023 Install wing tip ribs - (3 hours)

Category: Wings

Match drill, countersink, and rivet outboard rib to left wing tip. Using a bright light inside the tip outline the position of the stiffening rib. Match drill and epoxy stiffening rib to left wing tip.

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Jun 04, 2023 Fit left wing tip - (4 hours)

Category: Wings

Mount left wing tip to wing. Match drill tip to wing.

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Jun 04, 2023 Attach left aileron to wing - (4 hours)

Category: Wings

Attach left aileron to wing hinge brackets and pushrod to aileron bellcrank. Affix aileron neutral position fixturing bracket.

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Jun 03, 2023 Attach aileron hinge brackets - (3 hours)

Category: Wings

Attach inboard and outboard aileron hinge brackets to left and right ailerons

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Jun 02, 2023 Begin panel wiring - (2 hours)

Category: Avionics

Review videos on Stein-Air website for how to wire connectors. Begin wiring at autopilot control.

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Jun 02, 2023 Ailerons and Flaps delivered - (1 hour)

Category: Wings

Received quick build flaps and ailerons. Unpack and inspect no damage.

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Jun 01, 2023 Panel wiring preparation - (3 hours) Category: Avionics

Review avionics schematic provided by Stein-Air to identify how the individual LRUs interconnect (autopilot control, audio panel, comm radio, transponder, two displays, engine monitor, ADS-B, and AHRS module. Review Garmin G3X installation manual to identify how to connect wiring and shields to LRU connectors. Inventory LRU back shell connector kits.

May 28, 2023 Mount Alternate Air Door cable pass through - (2 hours)

Category: Fuselage

Drill firewall for alternate air door firewall pass through fitting. Tight space between mounted throttle fitting and vertical angle brace. Trim edge of throttle firewall pass through fitting and starter solenoid mounting bracket reinforcement plate to accommodate pass through fixture.

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May 28, 2023 Fabricate secondary battery hold down strap - (3.5 hours)

Category: Fuselage

Fabricate hold down strap for secondary battery. Scuff and prime strap. Removable by pulling hinge pins.

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May 28, 2023 Fabricate new avionics tray rails - (4 hours)

Category: Avionics

Mount avionics tray mounting rails.

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May 27, 2023 Test fit secondary battery box - (8 hours)

Category: Avionics

Scuff and prime battery box. Scuff and prime all forward upper fuselage subpanels, ribs, and attaching artifacts. Mount battery box to fuselage. Drill avionics support angles for trays. The drilled holes were imprecisely placed and this work was scrapped and new supporting angles fabricated and riveted to instrument panel.

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May 27, 2023 Cut avionics subpanel mounting hole - (3 hours)

Category: Avionics

With avionics trays temporarily mounted to panel mark the location of a hole in the subpanel for access to rear connectors. Cut right side of instrument panel to at the headphone jack and fresh air vent to allow panel to be installed without interference with center section vertical bulkhead. Prior the panel needed to be forced to slip past the bulkhead.

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May 26, 2023 Battery box for secondary bus - (8 hours)

Category: Avionics

Fabricate a battery box to hold the 12 AH battery supplying power to the secondary avionics bus and Lightspeed ignition.

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May 23, 2023 Avionics and display mounts - (3 hours)

Category: Instrument Panel

Drill and rivet display mounts to instrument panel. Fabricate angle mounts for avionics trays and rivet to instrument panel. Place avionics in panel for test tit.

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May 21, 2023 Complete match drilling forward top skin - (4 hours)

Category: Fuselage

Clamp forward upper fuselage skin to workbench and roll form it around a pipe to add bend. Cleco and match drill the forward upper fuselage skins to fuselage and firewall..

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May 19, 2023 Fabricate panel mounting angles - (1.5 hours)

Category: Instrument Panel

Fabricate panel to fuselage mounting angles

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May 19, 2023 Test fit forward upper fuselage skin - (1 hour)

Category: Fuselage

Cleco forward upper fuselage skin to fuselage in preparation for match drilling and dimpling to airframe and identify precise instrument panel location prior to drilling holes for panel to fuselage mounting angles.

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May 19, 2023 Rivet left wing lower outboard skin - (3 hours)

Category: Wings

Complete riveting left wing lower outboard skin.

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May 18, 2023 Replace right wing vent line - (2 hours)

Category: Fuselage

Right wing fuel tank vent line interfered with subpanel. Fabricate new vent line fitted to avoid interference.

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May 18, 2023 Begin riveting left wing lower outboard skin - (2 hours) Category: Wings

Begin riveting left wing lower outboard skin. Rivet skin to aft wing spar

May 14, 2023 Replace left wing tank vent line - (2 hours)

Category: Fuselage

Original left wing vent line interfered with subpanel. Fabricate and install new vent line.

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May 14, 2023 Prepare left wing skin - (4 hours)

Category: Wings

Prepare left wing lower outer skin: Match drill, scuff with Scotch Brite, dimple, and prime inside surface. Rough cut pitot mast hole.

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May 14, 2023 Discover leading edge wing ding - (1 hour)

Category: Wings

Upon placing left wing on bench discovered dent in leading edge resulting from a dropped bucking bar when mounting the pitot mast earlier. Confer with technical advisor, Tom Berge, for repair strategy. Also send email to Vans requesting advice.

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May 13, 2023 Rivet wing skin - (6 hours)

Category: Wings

Started with 2 hours on 5/12 and finished on 5/13 rivet lower right outboard wing skin. Place left wing on workbench.

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May 12, 2023 Assemble main tires and tubes on rims. - (2 hours)

Category: Wings

Assemble main tires and tubes on rims with brake disks. Inflate tires to 35 psi. Place tape over exposed wheel bearings.

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May 12, 2023 Fuselage cutout for gear legs and drill mounting holes - (4 hours)

Category: Wings

Trim lower fuselage skin to create space for the gear legs per direction from Vans. Drill engine mount holes to final 3/8" diameter and attach engine mount to fuselage using hardware bolts.

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May 11, 2023 Install left wing aileron and flap gap seals - (3 hours)

Category: Wings

Match drill, deburr, and dimple left wing aileron and flap gap seals. Rivet gap seals except for flap seal to aft spar which will need assistance.

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May 10, 2023 Mount Left Wing Aileron Brackets - (2 hours)

Category: Wings

Mount left wing aileron brackets. Install inboard aileron bracket reinforcement kit per service bulletin. Burnish and prime left wing flap and aileron gap seals.

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May 07, 2023 Mount ADS-B receiver and more - (8 hours)

Category: Avionics

Create mount for ADS-B receiver. Create mount for Engine Management System. Rivet Lightspeed ignition mounting to instrument panel ribs,

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May 06, 2023 Mount Lightspeed Ignition Modules - (6 hours)

Category: Engine

Devise a way to mount the Lightspeed brainboxes to the instrument panel ribs using piano hinges and aluminum bar. Modules can be removed by pulling the hinge pins. Hinge pins held in place with a zip tie. Defer priming and final riveting until the EMS and ADS-B modules also mounted. Due to slight variations in tolerances the modules are not interchangeable right for left.

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May 03, 2023 Right wing - (2.5 hours) Category: Wings

Finished dimpling the right lower outer wing skin, scuffed inside surface with Scotch Brite, and applied primer. Completed riveting right wing flap gap seal to rear spar.

May 02, 2023 Right wing gap fairings and aileron bracket service bulletin - (10 hours)

Category: Wings

Drill out right wing inboard aileron hinge bracket and install hinge reinforcement brackets according to service bulletin. Match drill, dimple, and prime the right wing aileron and flap gap seals. Rivet gap seals to wing except for flap seal rivets to rear wing spar.

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May 01, 2023 Prepare flap and aileron gap seals - (4 hours) Category: Fuselage

Match drill, dimple, and prime right wing aileron and flap gap seals.

Apr 30, 2023 Fabricate aileron hinge brackets - (6 hours)

Category: Wings

Fabricate left and right aileron brackets. Rivet right wing aileron brackets to rear wing spar. Match drill right wing bottom outboard wing skin.

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Apr 29, 2023 Install copper bus bar - (1 hour)

Category: Firewall

Fabricate and install copper bus bar connecting master contactor and starter solenoid.

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Apr 28, 2023 Complete aft top skin riveting - (2 hours)

Category: Fuselage

Complete riveting the aft top skin at and forward from the baggage compartment bulkhead.

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Apr 28, 2023 Mount heat control cable and electrical components - (10 hours)

Category: Firewall

Drill firewall heater control cable penetration and mount the fitting and cable. Create doubler plate to mount the master contactor and starter solenoid to firewall. Add nut plates to firewall and firewall stiffener angles, and mount components.

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Apr 27, 2023 Rivet aft top fuselage skin - (4 hours)

Category: Fuselage

Cleco aft top skin to fuselage and rivet to fuselage except for rivets at and forward from the baggage compartment bulkhead.

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Apr 25, 2023 Horizontal Stabilizer trim pieces - (3 hours)

Category: Fuselage

Fit horizontal stabilizer trim pieces to fuselage. Match drill and dimple trim to fuselage holes. Trim about 1/16" to create a gap between the trim piece and HS.

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Apr 23, 2023 Rudder pedal brake lines - (2 hours)

Category: Fuselage

Install fittings to brake cylinders. Cut for fit the left and right brake lines. Check for fit in fuselage.

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Apr 22, 2023 Fabricate battery box and drill firewall penetrations - (8 hours)

Category: Fuselage

Started on 4/21 and finishing today. Fabricate battery box and install on firewall. Create steel template for drilling fire wall penetrations for DoubleTee firewall fittings. Locate and drill throttle, mixture, and propeller governor fittings and install on firewall.

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Apr 16, 2023 Paint fuselage interiorq - (2 hours)

Category: Fuselage

Mask and cover fuselage in preparation for painting. Wipe all surfaces to be painted with coarse Scotch Brite pad and wipe with tack cloth. Hired painter to paint the fuselage interior. Jeff did a fabulous job.

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Apr 11, 2023 Pick up removable interior panels from paint shop - (2 hours)

Category: Fuselage

Inventory and transport 30 removable panels, flooring, and seat backs to paint shop. Pick up painted parts.

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Apr 08, 2023 Attach fuel senders to mounting plate - (6 hours)

Category: Fuselage

Attach fuel senders with cork gaskets to fuel line mounting plates. Kit inventory provided two left tank sending units 385B. Install the right sending unit upside down. Bend float rods and install on senders. Attach right sender to left tank and left sender to right tank with floats facing outside. Verify float travel from minimum to maximum travel.

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Apr 08, 2023 Mount light control board - (6 hours)

Category: Fuselage

Fabricate mounting bracket for FlyLEDS "works" control circuit board. Attach bracket to fuselage.

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Apr 03, 2023 Fuel line mounting plates - (4 hours)

Category: Wings

Fabricate fuel sender and tank mounting plate gasket. Attach drop tubes with anti-rotation brackets. Seal drop tube brackets to mounting plates with Proseal.

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Mar 31, 2023 Fabricate Pitot Tube mast mounting bracket - (4.5 hours)

Category: Wings

Fabricate pitot tube mounting bracket. Ready to install.

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Mar 30, 2023 Fuel selector valve and lines - (4 hours)

Category: Fuselage

Mount fuel selector valve to valve mounting plate. Fit left and right fuel tank lines from the valve to outboard the fuselage. Temporary installation without flare fittings which will be added at final installation after installing the fuel filter and boost pump.

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Mar 25, 2023 Collect panels for painter - (2 hours)

Category: Fuselage

Collect all removable panels and cabin artifacts needing painting, label and catalog them prior to sending to the painter. Thirty items total.

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Mar 25, 2023 Fabricate stick boot rings - (2 hours)

Category: Fuselage

Fabricate two stick boot rings.

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Mar 25, 2023 Fabricate and install left fuel tank vent line - (3 hours)

Category: Fuselage

Fabricate and install left fuel tank vent line

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Mar 24, 2023 Right Fuel Tank Vent Line - (4 hours)

Category: Fuselage

Fabricate and install the right fuel tank vent line.

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Mar 19, 2023 Wiring for ELT and Pitch Servo - (4 hours)

Category: Fuselage

Route wiring from the empennage forward towards the pitch servo. Connect pitch servo wiring and route the wiring forward through the center tunnel. Wire the ELT except for the antenna, and run wiring forward through the center tunnel.

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Mar 18, 2023 ELT and Mag Sensor - (10 hours)

Category: Fuselage

Complete wiring the magnetometer connector. Fabricate a mounting plate for the ELT. Mount ELT to fuselage.

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Mar 17, 2023 Wiring to Tail Light and Conduit to empennage - (8 hours)

Category: Fuselage

Install conduit to carry wiring from the empennage forward to behind the baggage comparment. Install wiring tail light forward to the fuselage behind the baggage compartment. Rivet the rudder fairing.

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Mar 15, 2023 Tail light wiring - (4 hours)

Category: Fuselage

Add conduit to bottom of rudder tip. Drill hole through vertical stabilizer for tail light wire. Attach rudder to vertical stabilizer. Route tail light wire from empennage to tail light.

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Mar 13, 2023 Routing static line - (4 hours)

Category: Fuselage

Routed conduit along left side under the baggage floor and seat floor. Add cable ties to support static line leading to the conduit.

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Mar 11, 2023 Flaps and Static Port - (10 hours)

Category: Fuselage

Assembled flap mounting, added nut plates, and fit the side skirts. Mounted two static ports and routed line to the lower fuselage.

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Mar 10, 2023 Flap attach bracket - (6.7 hours)

Category: Fuselage

Make angles and plates for flap assembly. Fit bracket to fuselage and match drill. Attach flap motor to bracket and actuator. Rivet all flap bracket parts and nut plates. Attach nut plates to forward elevator push tube tunnel.

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Mar 06, 2023 Install flap actuator - (4 hours)

Category: Fuselage

Cut and drill 3 flap bearing blocks and install flap actuator in fuselage. Drill safety wire hole in the end of flap motor shaft.

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Mar 05, 2023 Create carboard templates - (3 hours)

Category: Fuselage

Create cardboard templates for fuselage floor and side walls.

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Mar 04, 2023 Begin empennage wiring - (5 hours) Category: Fuselage

Install electric trim servo and wiring in elevator. Route wiring to rear bulkhead. Run rear tail light and strobe through empennage. Reinstall vertical stabilizer.

Mar 04, 2023 Install heat vent valve - (5 hours)

Category: Fuselage

Drill two 2" holes in firewall for heat valve. Use 2" hole saw and a piece of wood with 2" hole to prevent the hole saw center from wandering. Use slow speed, plenty of cutting oil, and constant pressure. Bend center cover air louvers. Clamp a stiff straight edge to the bend line and a wide putty knife inserted under the louver as a metal brake.

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Feb 24, 2023 Instrument panel layout - (10 hours)

Category: Fuselage

Working with UpNorth Aviation for the past month laying out the instrument panel. The panel is ready to cut out.

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Feb 19, 2023 Install control sticks - (4 hours)

Category: Fuselage

Install left and right control sticks.

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Feb 12, 2023 Aileron Trim - (5 hours)

Category: Fuselage

Fabricate aileron trim control and mount.

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Feb 11, 2023 Elevator tips - (2 hours)

Category: Empennage

Attach left elevator tip. Drill and dimple right elevator tip. Cleco elevator tip. Ready to rivet.

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Feb 11, 2023 Attach fresh air intakes - (4 hours)

Category: Fuselage

Install fresh air intakes to fuselage

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Feb 04, 2023 Steps and Brake Reservior - (3 hours)

Category: Fuselage

Drill firewall, attach nut plates, and brake reservoir to firewall. Rivet left and right steps with help from Xander.

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Feb 01, 2023 Install Stall Warn Hatch - (1.5 hours) Category: Wings

Dimple and rivet nut plates to hatch backing plate. Dimple hatch and wing hatch attach screw holes. Rivet hatch backing plate to wing and attach hatch.

Jan 23, 2023 Install Pitch Servo - (2 hours)

Category: Fuselage

Rivet pitch servo mount to center skin brace. Attach pitch servo to elevator bell crank.

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Jan 21, 2023 Install Roll servo, HS tips - (4 hours)

Category: Fuselage

Rivet the horizontal stabilizer fiberglass tips. Install the roll servo in the right wing.

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Jan 20, 2023 Fabricate aileron push rods - (3 hours)

Category: Wings

Test fit installing the aileron bell cranks in left and right wing. Fabricate two W-917 stick to aileron push tubes.

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Jan 11, 2023 Inventory Finishing Kit - (3 hours) Category: Fuselage

Received finishing kit yesterday. Inventory complete except for back ordered items.

Jan 01, 2023 Match drill panel angles - (4 hours)

Category: Fuselage

Add nut plates and cleco attach angles between panel and fuselage. This is a temporary setup before committing to using the supplied panel. Cleco the angle joining the center rib with the middle subpanel.

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Dec 31, 2022 Attach rudder pedals to rudder pedal assembly - (1 hour) Category: Fuselage

Attach 4 rudder pedals to the rudder pedal assembly.

Dec 31, 2022 Fit front deck - (6 hours)

Category: Fuselage

Make attach angles, plate, and stiffening angle. Drill center rib to firewall. Deburr and fit left, center, and right ribs, left and right outboard subpanels, and center subpanel to fuselage. Check partial fit of forward top skin to verify fit with center rib.

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Dec 18, 2022 Mainly Crotch Straps and VS tip - (7 hours)

Category: Fuselage

Drill to fuselage, deburr, install nut plates, and primer right and left crotch straps. Ready for riveting. Create a fiberglass 4 ply layup sheet to enclose the aft end of the vertical stabilizer tip. Cut and shape to fit inside tip. Trim rudder lower fiberglass tip to fit around rudder cable attach brackets. Drill rivet holes tip to lower rudder. Drill mounting hole for rear marker light/strobe.

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Dec 11, 2022 Mount Rudder to VS, install tail cone stiffeners - (6 hours)

Category: Fuselage

Mount Rudder to Vertical Stabilizer. File rudder stops to ensure 35 degree rudder deflection. Measured 46 1/8" from rudder trailing edge to outboard elevator trailing edge. Unbolt HS and VS from fuselage and deburr all mounting holes. Install left and right rear tail cone stiffeners F-00773A: Look up installation on Van's website because drawings did not show, layout on fuselage, drill, dimple, and rivet stiffeners to fuselage.

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Dec 11, 2022 Mount steps to fuselage - (1.3 hours)

Category: Fuselage

Cleco left and right steps to fuselage and bolts support blocks and steps to fuselage. Ready to rivet steps.

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Dec 10, 2022 Drill Rear VS Spar to bulkhead - (2 hours) Category: Fuselage

Drill vertical stabilizer rear spar to rear bulkhead F-712.

Dec 08, 2022 Drill horizontal and vertical stabilizer to fuselage - (2 hours)

Category: Fuselage

Drill vertical stabilizer front spar to F-981 attach plate. Drill horizontal stabilizer rear spar to Up elevator stop F-912C.

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Dec 07, 2022 Mount horizontal and vertical stabilizer to fuselage - (2 hours) Category: Fuselage

Fabricate and mount Up Elevator Stop F-912. Mount attach plate F-981 to horizontal stabilizer forward spar. Trim vertical stabilizer forward spar Clamp the vertical stabilizer rear spar to to the back of builkhead F-912. Adjust vertical stabilizer such that the hinge line is colinear.

Dec 05, 2022 Steps and Vertical Stabilizeer - (4 hours) Category: Fuselage

Drill left step support block and deburr step. Prime left and right step. Restore the F-750R,L rear baggage cover plate nuts to the bulkhead. Both steps ready for permanent installation.

Bolt F-981 attach plate to horizontal stabilizer forward spar. Trim VS-702 vertical stabilizer forward spar as depicted in DWG 27A. Fabricate elevator stop F-912D.

Dec 03, 2022 Mount Left Step - (8 hours)

Category: Fuselage

Complete drilling left step support block to floor rib. Drill 1 1/2" diameter holes through skin and two ribs, and trim two flanges to situate the step to the left fuselage. Remove F-650 rear side baggage cover; drilled out QB installed nutplates, to expose F-624 rib that will support riveting the step to the fuselage. Drill left step rivet and support blocks. Left and right step ready for priming and riveting.

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Dec 02, 2022 Start Right Step Mount - (3.3 hours)

Category: Fuselage

Drill 1 1/2" diameter holes through skin and two ribs, and trim two flanges to situate the step to the right fuselage. Remove F-650 rear side baggage cover; drilled out QB installed nutplates, to expose F-624 rib that will support riveting the step to the fuselage.

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Nov 28, 2022 Fabricate Elevator Pushrod - (4 hours)

Category: Empennage

Install F-635 bell crank. Fabricate F-790 pushrod. Mount the pushrod to the bell crank and elevator horns. With the elevator counterweights pinned to the horizontal stabilizer tips adjust the pushrod length by screwing in each rod end bearing until the bell crank is vertical. Tighten each rod end bearing jam nut. Remove the pushrod and store.

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Nov 27, 2022 Fit Horizontal Stabilizer to Fuselage - (6 hours)

Category: Empennage

Finish shaping HS-908L and R attach angles. Rivet angles to front horizontal stabilizer spar. Clamp the horizontal stabilizer to the fuselage and align it perpendicular to the longitudinal axis by measuring distance from each tip to the corner of the firewall. Measured distance for both 153 1/16". Drill the attach angles to the longerons and F710B angle. Fabricate the F-798 shims and slip them between the attach angles and the longerons. Raise the rear horizontal stabilizer spar using an 11/32" drill bit for a spacer. Clamp the rear spar to the F-711C bars and drill the attach holes. Measure again the distances from each horizontal stabilizer tip and the firewall corner. Left measures 152 7/8" and right measure 153 1/8".

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Nov 23, 2022 Drill Elevator Horns - (3 hours)

Category: Empennage

Fit elevators to horizontal stabilizer and pin in trail by clamping to the stabilizer tips. Measure the space between the elevator horns and create an aluminum spacer on the lathe that exactly fits between the horns and a #30 hole through the center. Remove the left elevator and drill a #30 pilot hole in the horn shown in DWG 27A. Remount the left elevator and clamp the counterweight arm to the stabilizer. Insert the aluminum spacer and align its hole with the pilot hole in the elevator horn. Drill through the spacer into the right elevator. Remove the spacer and enlarge both horn holes to full size. Measure the full up and full down elevator deflection.

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Nov 23, 2022 Fit elevators to stabilizer - (3 hours) Category: Empennage

Install rod end bearings on right and left elevators. Attach right elevator to horizontal stabilizer and lock position in trail. Make a drill bushing to fit inside VA-146 central bearing. Drill elevator horn to central bracket. Remove right elevator and mount left elevator and lock position in trail. Drill elevator horn to central bracket. Remove left elevator. Enlarge to 1/4" both elevator horn to central bracket mounting holes.

Nov 19, 2022 More stands - (5 hours)

Category: Workshop

Fabricated a tail cone support stand that fits inside the tail wheel socket. The fuselage can now be rolled freely. Create two stands to support the wing during installation. Experiment with plugging in the wing to the fuselage. Since the bottom skin is still not attached I did not fully insert the wing. Did verify the wing stands supports the wing during installation. Fabricated aileron and flap alignment tool.

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Nov 18, 2022 Created front fuselage stand - (3 hours)

Category: Workshop

Fabricated fuselage stand to stabilize the fuselage and facilitate moving during construction.

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Nov 17, 2022 Engine Delivered - (1 hour)

Category: Engine

Received engine from shipper. Inspected engine and accessories, and reviewed documentation.

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Nov 14, 2022 Inspect Quick Build Wings - (4 hours) Category: Wings

Inspect quick build wings for steps preparing the main spar, assembling the rear spar, preparing the wing ribs, assembling the wing skeleton, leading edge assembly, assembling the fuel tanks. Review steps to install the left fuel sender F-385 and the fuel pick up tube to the cover plate T-708.

Nov 12, 2022 Rivet rear bulkhead and rudder stops - (7 hours)

Category: Fuselage

Rivet rear bulkhead F-712 to fuselage except for lower, inside rivets. Need pull rivets. Rivet rudder stops to fuselage. Add lightening holes to rudder pedal brace F-6118. Drill 3rd rudder position position. Split side rudder pedal bearing blocks. Since steps and flap parts are on back order, the next step appears to temporarily mount the wings and set the wing incidence.

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Nov 11, 2022 Fit tail wheel mount and rear bulkhead - (4 hours)

Category: Empennage

Expand fuselage mousehole for tail spring mount WD-409. Bolt WD-409 to F-711. Fit rear bulkhead F-712 to fuselage and WD-409. Cleco and ready to rivet.

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Nov 10, 2022 Forward covers - (5 hours)

Category: Fuselage

Fit center floor F-982C, access plate F-982E, and heat baffle F-982C, and install nut plates and rivet. Rivet nut plates to fuel valve plate V-983A and screw to bulkhead F-904. Fit F-982C between center floor reinforcement angles and adjust to fit fuel valve cover F-983C. Drill F-982C to floor stiffener angles and firewall recess F-601K-1. Install all remaining nut plates. Do not trim fuel valve cover yet.

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Nov 09, 2022 Seat backs and rests - (4 hours)

Category: Fuselage

Rivet right and left seat backs and seat back braces. Add lightening holes to seat back braces. Match drill and dimple F-982E access plate and F-982 heat baffle to F-982C center cabin cover. Cleco nut plates to F-982C.

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Nov 08, 2022 Seat backs and rests - (4 hours) Category: Fuselage

Rivet right and left seat backs. Fabricate two seat back rests; ready for riveting and lightening holes.

Nov 07, 2022 Build right seat back - (3 hours) Category: Fuselage

Drill, deburr, and prime right seat back assembly. Ready for riveting.

Nov 06, 2022 Tunnel cover & seat backs - (10 hours)

Category: Fuselage

Riveted tunnel cover to side flanges and drilled to forward floor and attached nut plate. Completed preparing left seat; material cut, drilled, and deburred. Started right seat.

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Nov 03, 2022 Harness cable wear blocks - (4 hours) Category: Fuselage

Fabricate parts and install F-6114B&C cable wear blocks.

Nov 02, 2022 Baggage Compartment - (3.5 hours) Category: Fuselage

Drill in place the forward top skin F-774 to bulkheads and stringers. Skip steps installing the steps which are back ordered. Install nutplates on F-706

Oct 30, 2022 Fitting forward top skin and F-6111 ribs - (5 hours)

Category: Fuselage

Fit the F-7112 forward top skin to F-706 and F-707 bulkheads. Fit F-788 gusset. Ready to drill skin to bulkheads, stringers, and gussets. Trim and match drill F-6111 ribs to F-7112 skin.

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Oct 30, 2022 Fabricate and fit elevator bell crank - (2.5 hours) Category: Fuselage

Trim F-757 gussets per plan Assemble and install elevator bell crank. Remove and store for use later. Quick build verify bell crank support, fitting aft top skin, and installing F-565L and R gusset plates.

Oct 29, 2022 Mount Rudder pedals in fuselage - (5 hours)

Category: Fuselage

Drill mounting holes in rudder pedal end blocks and center support block. Cut center support block per drawing. Mount rudder pedals in fuselage and drill mounting holes 3" from firewall. Cut and drill rudder pedal support bracket and match drill for mounting to firewall. Drill support bracket to fit center support block. Inspect quick build fuselage steps: install floor stiffeners, framing baggage area, riveting forward side skins, finishing forward fuselage and longeron details, installing forward fuselage gussets, and installing should harness anchors. Mark side gussets F-757 to trim for cutout per drawing.

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Oct 25, 2022 Rivet rudder pedals - (4 hours) Category: Fuselage

Machine counter sink and rivet left seat right and left rudder pedals.

Oct 23, 2022 Fuselage - (8 hours)

Category: Fuselage

Fabricate left and right F-792 rudder stops. Paint WD-409 tail spring bracket; ready to install. Fabricate left rudder pedal; ready to rivet. Inspected fuselage related to preparing and assembling the center fuselage and note instructions for preparing the step for installation (steps are back ordered), joining rear and center fuselage assemblies, adding the forward fuselage, installing auxiliary longerons and forward bulkheads.

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Oct 22, 2022 Rivet Seat Adjustment Parts - (2 hours) Category: Fuselage

Bend seat adjustment plates with 4 degree bend per drawing. Rivet F-705J angle, F-705K plate, and F-705L seat adjustment supports to F-705F channel for right and left seats.

Oct 20, 2022 Aero Sport Power Build School Day 3 - (6 hours)

Category: Engine

Aero Sport Power Build School Day 3. Witness attaching propeller and remaining cabling and plumbing. Add oil to engine. Engine run for approximately 2.5 hours in three test runs with power between 70-100%.

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Oct 19, 2022 Aero Sport Power Build School Day 2 - (5 hours)

Category: Engine

Aero Sport Power Build School Day 2. Assemble valve lifters, push rod tubes, pushrods, and rocker arms. Attach oil return lines and intake manifolds. Attach throttle body to crank case sump. Observe engine being mounted to test stand, attaching instrumentation, fuel, oil, and electrical cabling.

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Oct 18, 2022 Aero Sport Power Build School Day 1 - (8 hours)

Category: Engine

Attend Aero Sport Build School in Kamloops, BC CA. Day 1: Assemble crankshaft, connecting rods, bearings, camshaft and join crankcase halves. Assemble accessory housing including timing gears, oil pump, oil filter mount, fuel pump, vacuum pad, and prop governor pad. Assemble pistons, wrist pins, and cylinders. Attach crankcase sump.

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Oct 15, 2022 Drill WD-409 keeper rivet holes - (3 hours) Category: Fuselage

Fit F-712 bulkhead and drill two rivet keeper holes through F-712 and WD-409

Oct 14, 2022 Begin WD-409 installation - (4.5 hours) Category: Fuselage

Relieve F-779 skin to make room for tail wheel spring mount tube. Match drill WD-409 to F-711

Oct 13, 2022 Inspect Bulkheads - (3 hours) Category: Fuselage

Deburr, machine countersink, and prime seat adjustment parts. Need to bend F-705K with 4 degree angle prior to riveting to fuselage. Inspect quick build bulkheads F706, F-707, F-708, F-709, F-710, F-711, and F-712. Remove F-712 bulkhead and review WD-409 tail wheel spring mount installation.

Oct 12, 2022 Seatback fabrication - (4 hours) Category: Fuselage

Fabricate two each F-705J, F705K, and F-705-l seat adjustment supports Inspect F-705 bulkhead construction.

Oct 10, 2022 Assembling F-904 Bulkhead - (1.5 hours) Category: Fuselage

Verify quick build assembly: F-904A,B,C,D snap bushing holes 5/8", F-904C-L&R bulkhead assembly, rivet F-904C, F-904D, and F-904G. Fit WD-610, WD-611, and WD-612; filed WD-610, W-D612, and both brass bearings to fit WD-611,

Oct 09, 2022 Assemble F-601 Firewall - (6.5 hours) Category: Fuselage

Step through F-601 firewall assembly instructions to verify quick build construction and familiarize with parts, and drawings, Fabricate F-601 TD brake line bracket, match drill, machine countersink, prime, and rivet to firewall. Drill two 7/16" holes through bracket and firewall for brake line fittings, Match drill and dimple firewall recess F-601K-1.

Oct 08, 2022 Inventory Wings - (5.8 hours) Category: Wings

Complete fuselage inventory. Perform and complete the wings inventory. Generate an inventory discrepancy list,

Oct 07, 2022 Inventory Fuselage and Wings - (5 hours) Category: Fuselage

Receive quick build wings and fuselage, Store parts in hangar and begin inventory,

Oct 06, 2022 Build Wing Cradke - (4 hours)

Category: Workshop

Build wing cradle, Fuselage and wings scheduled to arrive tomorrow.

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Oct 01, 2022 Prepare hangar for QB fuselage and wings - (2 hours) Category: Workshop

Clean hangar and prepare for receiving quick build fuselage and wings this week.

Jul 13, 2022 Cut Trim Tab Rod - (2 hours)

Category: Empennage

Cut the trim tab actuating rode and verify travel up and down.

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Jul 13, 2022 Mount Trim Servo Motor - (2 hours)

Category: Empennage

Attach trim servo motor to mounting brackets and cover plate.

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Jul 11, 2022 Assemble Trim Tab - (2.5 hours)

Category: Empennage

Rivet the lower trim tab spar and bottom trim tab skin. Glue two foam ribs inside trim tab skin with Proseal. Rivet the top trim tab spar, hinge, and top trim tab skin. Place trim tab in V-blocks.n

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Jul 10, 2022 Left Elevator & Trim Tab - (10 hours) Category: Empennage

Rivet gusset, bottom skin to elevator spar. Rivet bottom skin to elevator trim spar. Match drill bottom elevator skin and trailing edge to the top skin. Deburr and dimple the trailing edge skin and machine countersink the trailing edge. Match drill, deburr, and dimple overlapping skin stiffeners outboard of the trim tab. Apply proseal to trailing edge and cleco trailing edge and upper and lower skins to a match drilled stiffener angle. Match drill hinge to upper elevator spar. Trim trim tab horns for electric trim. Bend trim tab ends to close the trim tab inboard and outboard ends. Match drill bottom trim tab skin and trim tab spar, and top trim tab skin, hinge, and trim tab spar. Deburr and dimple trim tab skins and lower trim tab spar. Machine countersink the upper trim tab spar. Rivet the trim tab horns to the lower trim tab skin Trim two foam ribs to fit within trim tab and scuff the aluminum in preparation prior to installing the ribs.

Jul 08, 2022 Rivet Left Elevator - (8 hours) Category: Empennage

Deburr and dimple elevator spar, counterbalance ribs, root rib, trim tab spar, and skin, Back rivet stiffeners to top skin. Rivet top skin to spar, counterbalance to spar, and control horn to spar. Back rivet stiffeners to bottom skin. Rivet trim reinforcement plate to bottom skin.

Jul 07, 2022 Begin Assembling Left Elevator - (2 hours) Category: Empennage

Cleco left elevator skin to elevator spar, trim tab spar, counterbalance assembly, and root spar. Match drill all holes. Begin riveting counterbalance assembly.

Jul 06, 2022 Bend Elevator Trim Skin - (2 hours)

Category: Empennage

Create bending brake on workbench. Bend elevator trim skin to fit foam ribs and plywood clamps.

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Jul 06, 2022 Rivet Right Elevator Trailing Edge - (2.5 hours)

Category: Empennage

Rivet right elevator trailing edge.

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Jul 05, 2022 Create Elevator Trim Rib and Clamp - (1.5 hours)

Category: Empennage

Cut two elevator trim tab clamps from 3/4" plywood. Cut two elevator trim tab ribs from supplied foam. Both ribs left long on forward edge.

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Jul 03, 2022 Rivet Right Elevator Trailing Edge - (1.5 hours)

Category: Empennage

Apply proseal to trailing edge wedge and cleco skins and trailing edge to angle stiffener.

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Jul 02, 2022 Rivet Right Elevator - (7.5 hours) Category: Empennage

Rivet stiffeners to top and bottom right elevator skin. Rivet top and bottom elevator skin to spar. Rivet elevator outer rib to spar. Partially rivet elevator skin to inboard and outboard ribs. Match drill trailing edge wedge to trailing edge elevator skin. Dimple trailing edge skin and machine countersink trailing edge wedge. Deburr and clean skin and wedge surfaces. Ready to proseal wedge and trailing edge.

Jun 29, 2022 Right Elevator Skeleton - (3 hours) Category: Empennage

Deburr and dimple right elevator skin, ribs, and spar. Rivet counterbalance ribs and skins. Rivet elevator horn to spar and inboard rib.

Jun 28, 2022 Right Elevator & Rudder - (5 hours) Category: Empennage

Match drill right elevator skin, spar, and ribs. Ready to deburr and dimple. Form the rudder leading edge, match drill, deburr and rivet. Rudder complete except for tip.

Jun 27, 2022 Rivet rudder trailing edge - (2 hours)

Category: Empennage

Clean proseal from rudder trailing edge rivet holes. Rivet rudder trailing edge using a hand squeezer with dies ground to match the rudder trailing edge angle.

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Jun 25, 2022 Begin building right elevator - (6 hours) Category: Empennage

Assemble left and right elevator counterbalance arms; match drill, debur, and dimple parts. Dimple right elevator skin for stiffeners. Assemble right elevator skeleton and cleco to right elevator skin.

Jun 24, 2022 Rivet rudder trailing edge and skin to ribs - (4.7 hours)

Category: Empennage

Clean rudder trailing edge and skin. Attach trailing edge with proseal and cleco to supporting angle. Rivet rudder skins to ribs. Flute left and right elevator wing tip ribs and fit counterbalance skin.

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Jun 23, 2022 Rivet rudder skeleton and skin - (5 hours) Category: Empennage

Rivet rudder skeleton and install rudder counterweight. Rivet rudder skin to spar only. Defer riveting rudder skin to ribs until after the trailing edge has been completed.

Jun 22, 2022 Prepare rudder skins and trailing edge - (2.5 hours) Category: Empennage

Dimple rudder skins. Machine countersink trailing edge. Fit rudder counterweight to counterweight rib. Fabricate counterweight hold down strap.

Jun 21, 2022 Match drill and deburr rudder - (2.5 hours) Category: Empennage

Match drill rudder skins and skeleton. Deburr holes and dimple ribs.

Jun 19, 2022 Rivet VS skin, assemble rudder - (6 hours)

Category: Empennage

Rivet VS skin to VS spar and ribs. Rivet rudder stiffeners to rudder skins. Cleco rudder skins to skeleton. Ready to match drill.

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Jun 18, 2022 Assemble Vertical Stabilizer - (6.5 hours)

Category: Empennage

Rivet VS spar, doubler, ribs, hinge brackets. Cleco VS skin to spar and ribs.

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Jun 17, 2022 Build Vertical Stabilizer - (3.3 hours) Category: Empennage

Flute ribs. Cleco front and rear spars, spar doubler, ribs, hinge brackets. Match drill and debur all holes.

Jun 09, 2022 Match drill right elevator skin and skin stiffeners - (2 hours) Category: Empennage

Match drill right elevator skin and skin stiffeners. Mount the C-Frame to allow clearance to dimple elevator skins.

Jun 09, 2022 Prep right elevator skin - (2 hours) Category: Empennage

Remove blue film from rivet lines and cleco skin stiffeners to skin in preparation to match drill.

Jun 07, 2022 Start Rudder Skeleton - (4 hours) Category: Empennage

Cleco and match drill rudder skeleton up to attaching the rudder skins. Still awaiting tape before back riveting the stiffeners to the rudder skins.

Jun 07, 2022 Finished HS - (1.25 hours) Category: Empennage

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Jun 07, 2022 Finished riveting hs - (1.25 hours) Category: Empennage

Finished riveting hs

Jun 06, 2022 Rivet HS skins to ribs and rear spar - (4.5 hours) Category: Empennage

Rivet HS skins to ribs and rear spar

Jun 05, 2022 Rivet HS skin to forward spar - (1.5 hours) Category: Empennage

Completed riveting left and right HS skin to forward spar.

Jun 04, 2022 Rivet HS skin to front spar - (2 hours) Category: Empennage

Rivet HS skin to front spar.

Jun 04, 2022 Rivets Category: Empennage

Jun 04, 2022 Rivet he skin Category: Empennage

May 23, 2022 Rivet front HS spar to nose ribs - (2 hours) Category: Empennage

Rivet front HS spar to nose ribs.

May 22, 2022 Prepare to rivet HS skin to spars, - (4 hours)

Category: Empennage

Rivet mid span ribs to front HS spar. Cleco front spar to skin. Ready to rivet

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May 21, 2022 countersinking, nose ribs, elevator trim access plate - (12 hours)

Category: Empennage

Machine countersink both horizontal spars. Rivet elevator nose ribs to skin. Dimple left elevator skin. Countersink and Install nut plates on elevator trim access panel.

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May 18, 2022 Elevator, rudder preparaton - (5 hours)

Category: Empennage

Drill and debur elevator and rudder spars. Debur and cleco rudder skin stiffeners.

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May 17, 2022 Empennage assembly - (6 hours)

Category: Empennage

Rivet front horizontal spar. Cleco the rear spar and ready to rivet.

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May 16, 2022 Empennage parts preparation - (5 hours) Category: Empennage

Finished match drilling rib and spars. Disassemble ribs, spars, hinge brackets. Deburr all holes and edges.

May 15, 2022 Horizontal Stab - (6 hours) Category: Empennage

Cleco forward and rear horizontal stab spars and ribs. Match drill ribs, elevator hinge brackets, doubler.

May 14, 2022 Received Kit-Inventory - (4 hours) Category: Empennage

Received empennage. Performed kit inventory. All parts accounted for except vertical stab spar back ordered.