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Project: cellison -
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Builder Name:	Craig Ellison -

Project:	Bearhawk - "B" - VIEW REPORTS
Total Hours:	964.75
Total Flight Time:
Start/Last Date:	Nov 19, 2022 - No Finish Date
Engine:	Lycoming YIO-540-D4A5
Propeller:	Hartzell Trailblazer

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

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May 02, 2024 Windscreen - (2 hours)

Category: Fuselage

Fabricated two side trim pieces for the windscreen edge where it meets the window out of .025 and painted the back flat black. I also removed the windscreen fairing and painted the back side black as well as the inside of the tract.

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May 01, 2024 Windscreen - (2 hours) Category: Fuselage

Started the trimming process on the aft edge of the windscreen on both sides where it will attach to the fuselage tabs and meet up with the pilot/co-pilot window. Used Devon's sheer to cut >025 AL sheet for the trim.
Ordered longer machine screws for the windscreen fairing and plexiglass drills from ACS.

Apr 30, 2024 Windscreen attachment fairing - (01 hour)

Category: Fuselage

Replaced boot cowling and windscreen . I will need longer screws for about 8 of attachment points. I then remounted the right copilot door and window th see how that was going to fit together . That's as far as I got. There's work to be done in this area.

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Apr 26, 2024 Glare shield paint - (1 hour) Category: Paint / Decals

Masked the remaining sections of the boot cowl and painted mat black for behind the windscreen.

Apr 25, 2024 Windscreen attachment fairing - (6 hours)

Category: Paint / Decals

Worked on getting the windscreen back into the fairing and assembly back on the fuselage in the proper placement. Once I had it in place I marked out where the attachment screws were to go and drilled with #40 and temporarily fixed with clicos. I then countersunk the holes in the fairing to allow for dimpled washers and removed the windscreen. I then enlarged the location holes in the boot cowl and drilled for fixed nuts. The boot cowl pieces were them removed and de-burred and fixed nuts were riveted with solid rivets where I could reach and 3/32 counter-sunk pull rivets for the rest.
I the masked the boot cowl parts and painted the area behind the windscreen and in front of the instrument panel with mat black paint.

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Apr 24, 2024 Flaps, Ailerons EcoFill and EcoPrime - (6 hours)

Category: Paint / Decals

Applied EcoPrime to the flaps and ailerons and windnscreen fairing.
Also sprayed EcoPrime on both wing tips.

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Apr 23, 2024 Aileron EcoFill - (2 hours) Category: Paint / Decals

Sanded both ailerons and applied the last cross coat of SuperFill .

Apr 23, 2024 Wing tips - (1 hour) Category: Wings

Finished up the left wing tip getting all the mounting holes opened up to accept the dimpled washers.
Then I opened a hole in the strobe mounting plate to allow the connector to pass through .

Apr 23, 2024 windscreen attachment fairing - (2 hours) Category: Fuselage

Sanded the super fill. There were some areas of unmixed filler so I dug those areas out and added new.

Apr 22, 2024 windscreen attachment fairingreen - (2.5 hours)

Category: Fuselage

Finished up trimming the windscreen attachment fairing sanded the edges even and added super fill.
Finished up adjusting the the right wing tip attachment holes for dimpled washers.

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Apr 21, 2024 windscreen attachment fairingreen - (2 hours)

Category: Fuselage

Trimmed the windscreen attachment fairing to approximately 1" flange on each leg. Then I filled the fuselage side gaps with flex/resin and laid up two layers of BID and peal ply. I then put it back on the boot cowl to allow it to cure in place.
Installed the plexiglass in the left side passenger window.
Started the countersinking the wing tip screw holes to accept #8 dimpled washers and screws. Many had to be adjusted to match up .

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Apr 20, 2024 wing closing - (2 hours)

Category: Wings

Finished up closing the right wing skin riveting. Also riveted the aileron cove close-out .

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Apr 09, 2024 Wing closing - (3 hours)

Category: Wings

Continued the riveting of the right wing skin to aileron cove close out. After removing the aileron cove panels I de-burred all holes and dimpled . Got the lower skin done.

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Apr 09, 2024 Windscreen attachment fairing - (1 hour)

Category: Fuselage

I removed the windshield and attachment fairing from the fuselage using a plastic spatula so as not to gauge the paint through the tape. Then I gently used the same technique to remove the fairing from the windscreen . Came off beautify . I then make 1" back from the transition both on the windscreen and fuselage side, ready for trimming .

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Apr 08, 2024 wing closing - (4.5 hours)

Category: Wings

Continued riveting the trailing edge of the right wing. Attache the wing tip support rib and associated nut plates. Began fitting the aileron cove covers, laying out and drilling the trailing edges for rivets.

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Apr 08, 2024 Windscreen attachment fairing - (1 hour)

Category: Fuselage

Removed the peal ply from the cured windscreen attachment fairing. I mixed up a batch of epoxy/micro and smoothed the transition on the sides of the fairing where the windscreen protruded out proud of the fuselage . Also filled other obvious voids. Peal ply applied .

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Apr 07, 2024 Windscreen fairing - (4 hours)

Category: Fuselage

Today was the day for fabricating the windscreen attachment fairing. I applied 3m ultra thin masking tape on the boot cowl then overlayed that with packing tape and release wax. Likewise the plexiglass on the bottom where it meets the boot cowl. I then laid up mixed up the west systems epoxy 5/1 ratio and made up a u-chanel around the bottom edge of the windscreen . Once it had started to cure I placed the windscreen on the fuselage and clamped to place. I then laid up four layers of fiberglass from the top of the u-chanel on the windscreen and extending onto the boot cowl approximately 3 inches . I then applied peal ply and left to cure fully.

More right wing bottom skin riveting. Attaching the trailing edge stiffener.

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Apr 04, 2024 Wing closing - (6.5 hours)

Category: Wings

Finally got back to the build after going to Mexico . Randy came over to help with the closing of the right wing. We got the first 11 rows of rivets done before he had to leave. I did on more row on my own which went very slow but I didn't make any smiles in the wing skin. I should be able to finish out by myself or have Noni help.
After a late breakfast I continued riveting the wing skin and got back to the aft spar. This included all the fixed nuts around the fuel tank bay.

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Mar 07, 2024 ADS-B antenna - (2 hours) Category: Avionics

Mounted the ADS-B antenna on the bottom of the fuselage with the provided hardware and attached the coax cable from the ADS-B unit mounted with the ELT.
Supported the pitot/AOA tubing where it joins the probe to the adjacent rib using zip ties through a short section of vacuum tube material. It was subject to vibration motion and I feared fatigue cracking of the aluminum tubing.or loosening of the friction fittings.
Got out the lift strut for the right wing and placed in position on the attachment point on the wing to lay out where to make the opening for the aileron control cable to exit the wing and down the strut.

Mar 05, 2024 Wing rotisserie - (1 hour) Category: Wings

Attached the spreader bars from the wing rotisserie on to the wing using the fuselage attachment points at the wing root and the hardware from shipping container.
Swept the shop and prepared the right wing for closing.

Feb 29, 2024 Wing tip - (3.5 hours) Category: Wings

The adhesive that I used to bond the wing tip trailing edge seems to have finally cured so I mounted the left and cut of the excess length to match the aileron. Also adjusted the gap between the end of the aileron and the wing tip to give a even gap between the two.
Once that was done I started the process of riveting the wing tip support rib to the wing. Many of these holes needed dimpling or counter sinking.
Now the wing is finished with the riveting part.

Feb 27, 2024 Aileron cove close out - (3.5 hours)

Category: Wings

Started riveting on the aileron cove close out. Finished the two inboard sections. The outboard section intersects with the wingtip support rib and will need some figuring out.

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Feb 26, 2024 Aileron close out - (5 hours)

Category: Wings

Finished the last 4 rivets on the wing trailing edge. I had to remove the two flap hinges to allow squeezing the rivets.
I was able to find the structural adhesive at Dave's hanger and I first removed all the epoxy/flox from the wing tips and sanded the area with 36 grit. I then mixed using the mixing tip supplied and clamped together. Time will tell if it will adhere .
Then started fitment of the aileron cove close out. I attache with clecos the measured out rivets lines on the top and bottom where it will attache to the wing skin. I the drilled and de-burred all the holes the dimpled all to receive flush rivets. It's ready to permanently attach.

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Feb 25, 2024 Trailing Edge Riveting - (3 hours) Category: Wings

Almost finished the trailing edge riveting on the left wing. I have two behind the aileron hinge which I'll have to remove to get at and one next to the inboard flap hinge with a split shop head which I'll need to drill out and squeeze again.

Feb 21, 2024 Left Wing - (.75 hour) Category: Wings

Finished the fuel tank bay skin riveting with nut plates. All that remains is the trailing edge riveting and the wing will be closed up.

Feb 20, 2024 Wing closing - (4 hours)

Category: Wings

Continued with closing the left wing. Got most of the wing skins with nut plates. Just the aft edge of the fuel tank bay left. Then the trailing edge and stiffener at the flap section.

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Feb 19, 2024 Closing Left Wing - (7 hours) Category: Wings

Randy came over and helped me start closing the left wing. It's a two person operation at first then one person can do it bucking one hand and air gun in the other. He helped me get to the last five rows then I was able to do it two handed working through the lightening holes in the rear spar. I then moved to the panel aft of the fuel tank. This became a nightmare due to me locating the Pitot and AOA tubing and aux tank fuel line(future possible use) with little or no room to place a bucking bar. I had to remove the pitot tube and the fuel line at the wing root , drive the rivets the replace both. The remaining rivets I should be able to get with the squeezer placing nut plates as I go.

Feb 18, 2024 Wind screen - (3 hours)

Category: Fuselage

Re-attached the boot cowl panels and started the wind screen fitment. I trimmed back the top edge where it slides into the channel since it was about 3/4" too long. I sanded the edge round to allow it to slide in more easily . As it is it I still haven't been able to get to to seat fully. I trimmed the bottom edge where it meets the cowl. This I think I'm done with this part.
I temporarily slid the mass balance tubes into the left aileron and remounted it. Defiantly nose heavy . I put some cable stops on the trailing edge to balance it and weighed then and it was 7.8 oz. I think the finish paint will weigh that much.

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Feb 16, 2024 Aileron counter balance - (1 hour)

Category: Wings

Smoothed up the ends of the aileron counter balance tubes and weighted them both. They came in 3g apart! One is 2602g and the other is 2605.
I remounted the aileron hinges and attached them the the wings. The weight I think will work out perfectly once I get the paint on them. Just a little nose heavy now.
I temporarily attached the wing tips and marked out the excess length mixed up some. epoxy/flox and bonded together the ends of both wing tips.

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Feb 15, 2024 Aileron counter balance - (1 hour)

Category: Wings

Mixed up the lead shot with epoxy and poured into both aileron counter balance tubes and mixed some micro to cap then covered with peel ply . The weight of the each tube approximately 5lbs 10oz.
Used the heat gun to remove the protective plastic coating from the left wing rivet lines in preparation for closing the wing.

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Feb 14, 2024 Wing Tips - (1.5 hours)

Category: Wings

One more round of filling pin holes and sanding on the wing tips.
Mixed up some epoxy/micro bubbles and filled the end of the aileron counter balance tube to smooth off the end and prevent any of the lead shot from becoming dislodged and ending up inside the aileron.

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Feb 13, 2024 wing Tips - (5 hours)

Category: Wings

More wing tip prep and primer. Lots of pin holes.
I opened up the holes for the mounting brackets in both the ailerons and flaps as well as the holes for the counter-weight in the ailerons.
Got out the lead shot for the ailerons and decided it. I have 5.5lbs for each and they just fit in the tubes provided. I mixed up some with JB weld and poured it down to one end to serve as a plug. Once it's set I'll mix the rest and fill the tube.
I removed the plastic film from the right wing that covered the rivet holes in preparation for closing the wing.

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Feb 12, 2024 Wing Tips - (2 hours)

Category: Wings

Sanded and applied two coats of EcoPrime with a foam brush . I then started filling the pin holes in one tip with glazing compound .

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Feb 11, 2024 Flaps EcoFill - (2 hours)

Category: Wings

Finished applying the second cross coat of EcoFill using a foam brush. Moved out of the lower part of the house and back into the shop. I will spray a final coat of EcoFill later when it warms up.
Crimped the aileron cable ends to the turnbuckle for each wing at the bell crank.

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Feb 09, 2024 Flaps EcoFill - (1.5 hours) Category: Wings

Got all but one side of flaps second cross coated with EcoFill

Feb 08, 2024 Aileron EcoFill - (2 hours) Category: Wings

Sanded both ailerons and applied a second cross coat of EcoFill. This will be the last for now. I will sand them later when it's warmer and spray on a final cross coat.

Feb 07, 2024 Flaps, Ailerons EcoFill - (3 hours)

Category: Wings

Since the shop is too cold to spray apply the EcoFill I decided to apply the first two cross coats with a foam brush and sand in between . I got the first coat on all the parts.

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Feb 06, 2024 Fabric weave fill - (2 hours)

Category: Wings

Filled the weave of the fabric on both flaps and ailerons with Ecobond diluted 30% by weight with distilled water.

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Feb 05, 2024 left flap fabric - (3 hours)

Category: Wings

Finished the taping on the left flap. It took longer that I thought it would since I had 9 tapes to do rather than 5 like I thought. Cleaned the bare fabric of both flaps and ailerons with Ecoclean ready to fill the weave .

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Jan 31, 2024 Left flap rib stitching - (5 hours)

Category: Wings

Started and finished the rib stitching on the left flap. Then started the taping. Gott a lot of it done.

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Jan 31, 2024 Left Flap fabric - (1.5 hours)

Category: Wings

Came beck and added a second layer of fabric to the leading edge, and shrunk to 350 degrees. Laid out the lines for the rib stitching and tapes on both sides.

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Jan 29, 2024 Left Flap fabric - (5 hours)

Category: Wings

Started the left flap fabric. Got the fabric wrapped and glued and realized I hadn't done the wrap correctly to double cover the leading edge.

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Jan 29, 2024 Right Flap Fabric - (1 hour)

Category: Wings

Glued on the last tape for the right flap which finishes this flap as far as the fabric goes.

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Jan 28, 2024 Right Flap tapes - (3 hours)

Category: Wings

Almost finished the taping on the right flap. Just have the trailing edge tape to do.

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Jan 26, 2024 Right flap rib stitching - (4 hours)

Category: Wings

Started and finished the rib stitching on the right flap. One more pass with the iron at 350 degrees. Laid out the tape lines. Ready to apply the finish tapes.

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Jan 25, 2024 Right Flap Fabric - (5 hours)

Category: Wings

Finished gluing the fabric to the right flap and then shrinking to 350 degrees and three passes at that temp. Laid out the rib stitching and applied the reenforcing tapes.

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Jan 25, 2024 Right Flap Fabric - (2 hours)

Category: Wings

Started the right flap fabric covering. I'm going to try double wrapping the leading edge on the flaps.

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Jan 23, 2024 Right elevator fabric - (1.5 hours)

Category: Wings

Finished tip taping on the right aileron.

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Jan 22, 2024 Right elevator fabric - (2 hours) Category: Wings

Continued taping on the right aileron.

Jan 21, 2024 Right aileron rib stitching - (2 hours)

Category: Wings

Started and finished the rib stitching on the right aileron. Then began the taping.

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Jan 19, 2024 Right aileron fabric - (4 hours)

Category: Wings

Started the covering of the right aileron. I was able to attache the fabric and get to full shrink at 350 degrees . Rib stitching next

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Jan 18, 2024 left aileron tapes - (2 hours)

Category: Wings

Finished the tapes on the left aileron.

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Jan 17, 2024 left aileron tapes - (2 hours)

Category: Wings

Started the taping process for the left aileron

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Jan 16, 2024 Left aileron rib stitching - (2 hours)

Category: Wings

Rib stitching completed on the left aileron

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Jan 15, 2024 Aileron fabric - (3 hours)

Category: Wings

Charlie gave me just enough fabric to cover a aileron so I could keep building while my fabric order was coming from Spencer. I was able to get it attached and through the last shrink of 350 degrees. I made two passes on 250, two passes on 300 and three passes on 350.
I did the wrap method using 4' of fabric.

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Jan 14, 2024 Flap & Aileron - (2 hours)

Category: Wings

De-burred the trailing edge parts on the right wing flap and aileron then riveted them in place. Not without some turmoil though. I was placing the final river in the flap and I noticed the trailing edge was dropping at the strange angle. Turned out when I had repositioned the trailing edge I had not got the overlap correct with the rib, so the only way to correct my mistake was to drill out almost half the rivets until I could reverse the overlap.

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Jan 12, 2024 Right wing aileron and flap - (2 hours)

Category: Wings

Attached the aileron and flap on the right wing and aligned the trailing edges of both and marked the wing tip for length. Then drilled to fix in position them in position the up-drilled to #30.
Did the first shaping of the super fill on the strobe light on the right wing tip.

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Jan 11, 2024 Flap & Aileron - (3 hours)

Category: Wings

Attached the left wing tip and did the initial shaping of the strobe/nav light mount.
I then attached the aileron and flap to the wing to check trailing edge alignment with the wing tip. I removed the temporary rivets in the aileron and it only needed a slight adjustment to align it with the flap. Then I marked the wing tip to align with both the flap and aileron . Then I drilled with #40 both trailing edges to secure their positions. Then up drilled to #30, disassemble both and de-burred all the parts, reassembled and riveted with pull rivets. Since the rivets I was using were steel I primered them before pulling them.

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Jan 10, 2024 wiring clean-up - (.5 hour)

Category: Wings

Added the last Molex terminal to the left wing strobe/nav wiring loom. Now just have to slip the wires from the strobe/nav unit itself when they're mounted on the wing tip.
Added super-fill to the wing tip strobe mount.

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Jan 09, 2024 Wiring - (3 hours)

Category: Wings

Added Molex terminals to the wing wiring, landing lights and strobes/nav lights. I almost completed just have one strobe/nav to do. Provided strain support for the wing tip wires as well.

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Jan 03, 2024 fuel lines - (4 hours)

Category: Wings

I located and opened the two remaining holes for the fuel lines going to the fuselage in the right wing root. I upsized the rest to allow removal of the lines with the end fittings in place.
I then upsized the holes in the wing for the AUX fuel lines to allow a one piece line to slide in. I was able to slide them in from the outboard towards the root this way. I flared the inboard end and added a AN fitting where it meets the rib and bulkhead fitting. I secured the outboard end with a adel clamp attached the closest rib. Both wings are done as far as fuel lines go.
I took another stab at riveting the landing light bracket on the right wing this time. I did better with no re-do's. The left wing where I enlarged the holes by having to drill out bad rivets, I used flush pull rivets. Landing light brackets are done.
I pulled the wire for the strobe/Nav along with the landing light and taxi wire through the chase in the right wing.

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Jan 02, 2024 Fuel lines - (5 hours)

Category: Wings

I installed the fittings in the fuel tank, finger strainer x2 and the fittings for the fuel sight gage.
I then Installed the tank in the right wing and located the holes in the wing root where the fuel lines and sight gage lines pass through to the fuselage . I fabricated a backer plate for the aft fuel line opening due to its size and location in the rib. Once that was riveted in place I located the hole for the fuel drain in the fuel tank cover and opened it to 3/4".
I also made holes in the ribs to allow placement of 3/8 fuel transfer line for future addition of AUX fuel tanks.
Located and opened the hole in the tank cover for the fuel drain fitting.

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Jan 01, 2024 Fuel tank covering , wing tips - (4 hours)

Category: Wings

Riveted on the nut plates for the fuel tank cover to the leading edge at the spar.
Up drilled the screw holes in the fuel tank cover to #27 then de-burred and dimpled the holes and followed with #6 screw head and flat set to get the finished recess.
I then bonded on the ply base plates that I had made up earlier for the strobe/nav lights to the wing tips using epoxy/flox paste and covered with peel ply.

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Dec 31, 2023 Fuel tank cover ,right wing - (5.5 hours)

Category: Wings

Started the process of drilling the 90+ screw and nut plate holes for the fuel tank cover for the right wing. Got all the holes drilled and de-burred. Mostly done with the dimpling , not quite. Tomorrow I should be able to get that done and attach the forward nut plates along the forward spar. It will be ready for wing closure then.

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Dec 29, 2023 Access panels right wing - (4.5 hours)

Category: Wings

Got the parts for the five remaining access panels and support rings de-burred before breakfast. In the afternoon I got to dimpling all the parts and the wing panels. Then I riveted the nut plates to the support rings. Then riveted the support rings to the wing. This took me to 5pm.

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Dec 28, 2023 Access panels right wing - (5 hours)

Category: Wings

More access panel work. In two work secessions I was able to get the remaining 5 panels where they were located in the proper location, all the holes were matched drilled on the panel and the wing to the proper size. Tomorrow I will proceed with de-burring, dimpling , then adding the nut plates to the retaining ring, then rivet the ring to the wing. Hope I have time for all that.

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Dec 27, 2023 Access panels right wing

Category: Wings

Moved on to the access panels. I started with the largest one at the aileron bell crank. I was able to complete the panel which took longer than expected since I had to completely figure out how the to the process again, having forgot since I did the left wing . Hopefully the other five won't take as long each to complete.

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Dec 27, 2023 Electrical chase - (1.5 hours)

Category: Wings

Located the position for the electrical chase using the tube mounts from Vans . Attached with 1/8 aluminum pull rivers. I then attached the chase tubing with zip ties. Nest I measured the wire for the landing light and optional taxi light and cut to length . I don't have enough of the three wire shielded for the strobe/nav lights so I'll have to order some.

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Dec 26, 2023 Aileron cable guides - (4.5 hours)

Category: Wings

Today I started with fabricating the doubler plates for the wing ribs that needed reinforcement after the holes for the aileron cables were opened up. Once they were done I set about riveting them in place. This took the morning since I had to stop mid stream and fix the compressor so I had air for the rivet squeezer/gun. In the afternoon I made up the cable for the aileron from the bell crank to the crossover turnbuckle in the fuselage. Once I installed the cable I noticed the most inboard hole was a little off and the cable was rubbing so I up drilled the hole to 3/4" and installed a new snap bushing.
I got the longer(25ft) SV network cable from Advanced and attempted to pull it through the chase with the other wires for the strobes/nav in place. No joy. I had to remove the terminals and pull those then re-pull all the wires at the same time. Having that accomplished I stopped for today.

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Dec 22, 2023 Right wing aileron actuation - (4 hours)

Category: Wings

Started making way for the aileron actuation cable in the right wing. I had kept the templates from the left wing which made the task much easier. I was able to get all the holes opened up and snap bushings placed in 7. I have the two outboard closest to the bell crank to finish up. For these I will need to fabricate doubler plates and rivet them to support the wing rib.

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Dec 21, 2023 Wing tip - (6 hours)

Category: Wings

First off today I riveted on the nut plates for the right wing tip.
I then started on the aileron and flap mechanisms. Sorted all the proper hardware for both and insert bearings on the aileron bell crank . Installed the pulleys for the aileron cable that goes down the lift strut. Had to remake/modify the cable guard as I had had to do for the left wing. ( Welded on a anti-rotation wing in the proper place/orientation ). Checked all the wing bolts for length and changed a few that were too short. I will torque tomorrow.

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Dec 20, 2023 Right wing tip - (3.5 hours)

Category: Wings

Moved on to the right wing tip. I upsized the locating holes done yesterday to #27 to fit the nut plate jig. Then drilled all the nut plate mounting holes with #40.
Next I upsized the screw holes to #17. Then de burred all the holes. Ready for attaching the nut plates.
I made up base plates for the Nav/strobe lights out of three ply and located them on the wing tips. I haven't decided on how I'll attach them to the wing tip yet.

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Dec 20, 2023 Ling lights - (1 hour)

Category: Wings

Got the wing light brackets into the left wing and put the LED in the bracket. Added the lens and all fit perfectly . I then tried to rivet the bracket to the upper and lower wing skins without success. I couldn't figure how to get a good result. I decided to give up for today and talk to Randy before proceeding .

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Dec 20, 2023 Landing lights - (.5 hour)

Category: Wings

Finished up assembling the second FlyLED landing light this morning. Went very smoothly . Fits the mount bracket from the Vans kit perfectly.

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Dec 19, 2023 Wing tip - (5 hours)

Category: Wings

Finished riveting the nut plates for the left wing tip attachment.
Opened up the right wing, removing the pull rivets placed for transit. They used steel rivets which were very difficult to remove, took over an hour to get them all out and even then I did some damage to the wing skins. Got out the right wing tip and started the install. Once I had it measured out and the attachment points marked I taped it in place and drill with the #40 to fix it in place. That's where I stopped. I've run out of sharp #40 drills.
I received my landing lights from FlyLED today and assembled on on the kitchen deck before bed.

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Dec 18, 2023 Wing tip - (4 hours)

Category: Wings

I finished up riveting the final five nut plates on the leading edge of the fuel tank cover.
Located and drilled pilot holes with #40 to position the left wing tip on the wing. After that I got to work doing all the up drilling and nut plate mounting holes then up sizing the screw holes to the final size for #8 screws. De-burred and only got one net plate riveted in place.

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Dec 17, 2023 Fuel tank nut plates - (1 hour) Category: Wings

Attached nut plates to the forward edge for the fuel tank cover at the spar. Got all but 5 done.

Dec 15, 2023 Fuel tank cover - (7 hours)

Category: Wings

I've been putting this off for some time now but today I decided to tackle it. I was able to dimple all the screw holes and mounting holes for the nut plates . I think it should work out and I don't have to worry about creating knife edges in the wing skins. Lots of drilling, up drilling , de-burring ,dimpling ,then re-dimpling with a #6 screw to get the proper countersink on the tank cover itself. I'll probably go ahead and attach the nut plates(countersunk) on the leading edge of the cover at the spar. The rest will have to wait until I close the wing.
Started lay out for the wing tip.

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Dec 14, 2023 Pitot/AOA plumbing - (2 hours)

Category: Wings

Ran the Pitot/AOA tubing from the pitot tube to the wing root. There I mounted bulkhead quick connects where they will mate to the tubing coming from the ADAHARS.

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Dec 14, 2023 Pitot mast - (1 hour)

Category: Wings

Noni helped me rivet the pitot/AOA mast to the lower skin of the leftt wing. She did the hammering and I the bucking.
Applied the double stick tape to the landing light lens backing plate and attached them to the lens themselves .

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Dec 13, 2023 Left wing electrical - (7 hours)

Category: Wings

Worked on the electrical conduit on the left wing. Once in place riveted place using lightening hole mounts from Vans. Then pulled the wires, (landing light power and ground, strobe/nav lights, and network cable for the remote magnetometer . I added the molex connectors for the lights at the wing root.
I then located where the pitot/AOA mast was going to go on the lower wing skin and using the template provided cut an opening for the mast and drilled the mounting holes with #40, de-burred and dimpled ready to riveting in place. Drilled the mast/head for #4 PK screws for fastening together.
Located the OAT probe on the underside of the wing adjacent to the remote magnetometer and drilled a 3/8" hole and after shortening the wires and sleeving with snake skin mounted with nylon nut and washer and connected it to the remote sensor.

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Dec 12, 2023 Landing lights - (2 hours)

Category: Wings

Finished smoothing the landing light opening in the right wing. Dimpled the holes in the leading edge to accept the rivets for the LED bracket. Trimmed and sanded the plexiglass then Matched drilled the lens and countersunk for the -6 flush screws .

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Dec 11, 2023 landing lights - (3 hours)

Category: Wings

Finished up what I can do on the left wing landing light until I get the LED's from FlyLED. Drilled the holes in the lens and counter sunk.
Started on the right wing light. Located the mounting holes and did the rough cut out of the light opening itself.
Finished up the ground wire from the battery to the firewall by crimping the end fitting and applied shrink tubing.

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Dec 05, 2023 wing landing light - (2 hours)

Category: Wings

Started the left wing landing light using the kit from Van's Aircraft . Using the template provided I laid out the holes for the mount as well as the opening itself for the plexiglass lens. Very uncomfortable filling cutting into the wing.
Dimpled the mounting brackets and riveted on the nut plates.

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Dec 04, 2023 Master relay diode - (1 hour)

Category: Workshop

I took the ring terminals off the diode that I purchased from ACS and attached the proper size ones on and lengthened the assembly by using a spade connector with shrink wrap over it. I then put it back on the relay in the proper orientation with the cathode going to the battery.

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Dec 01, 2023 shop cleaning - (2 hours) Category: Workshop

Now that I'm mostly done with the panel/avionics install I needed to clean the shop and reorganize the tools before switching over work on the wings.
Found out from Jonathon at AFS support that I had the diode for the master relay reversed. Getting that switched around might be tricky due to the fact that the ring terminals won't be the correct size for that orientation . Not sure if I can just cut them off the crimp on the correct ones.
Torqued the nut on the positive terminal to the ACM and installed a rubber boot to cover the post.

Nov 30, 2023 Wiring clean-up - (3 hours)

Category: Avionics

Installed the EarthX battery in the tray and secured it. All that's left to do for it is to decide on a location for the firewall ground bolt and bring the battery neg to it along with the ground wire from the ground block and ACM. I have the cables ready to put the ring terminals on already.
Spent most of the time tidying up the cable bundles/harnesses and supporting them so the don't fatigue.

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Nov 29, 2023 General wiring - (3 hours)

Category: Avionics

Finished up the molex termination of the landing light and Nav/strobes wires at the wing root.
Removed the fuel boost pump wires and added snakeskin to them and re-routed them to the general area by the gascolator.
Spent some time cleaning up the wire bundles and routing behind the panel. More to be done here.

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Nov 28, 2023 EMag wires - (1 hour)

Category: Avionics

Made up the EMag leads that will run forward to the engine area. These terminate at the key switch and are shielded wire. The shielding was joined and attached to the ground lug at the key switch.

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Nov 27, 2023 General wiring - (3 hours)

Category: Avionics

Wired the EMag power from the master relay to the EMag CB then added wire to the CB out to go forward to the engine area and magneto themselves .
Ran the pitot and AOA tubing from the ADAHRS module to the left wing root area.
Ran the wire from the key switch S or Start post to the starter relay.
Added a protection diode to the master relay. Was unable to attach to the battery side due to the ring terminal being too small.

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Nov 26, 2023 General wiring - (5 hours)

Category: Avionics

Interrupted the 8GA main power wire from the Alternator CB to the master contactor an place the shunt transducer to measure current. The sensor wires were connected from the EMS harness.
Ran the ground wire from the key switch to the grounding block on the right avionics shelf.
Starter power wire was run from the front Dsub at the ACM to the key switch.
Ran the Voltage sense wire from the EMS harness to the Power input post on the ACM.
Put the male connector end on the comm radio antenna coax.
Finished up the front and rear Dsub connectors to the ACM.

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Nov 25, 2023 Master contactor main lead - (1 hour)

Category: Avionics

Made up the main 8GA wire from the ALT circuit breaker to the mater contactor.

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Nov 16, 2023 Main bus wiring - (3 hours)

Category: Avionics

Made up the 2GA conductor from the battery to the master relay routing it through the instrument tray and down to the battery. Also made up the 2GA conductor from the master relay to the starter relay. Wired up the starter relay with protection diode. Not sure if I did it correctly. Think I'll send a picture of it to Advanced tech support and see what they have to say
Made up the 8GA wire from the master relay to the ACM.
Connected the wire from the Master panel switch to the master relay as well as the ground from same switch.
Located the ground block .

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Nov 15, 2023 ADAHRS - (2.5 hours)

Category: Avionics

Finished the mounting bracket for the ADAHRS unit. Mounted the unit and leveled it using washers. Did not need much , I think I only used one. I then plunged the static tubing into the back and attached the network cable to the ACM.
I then mounted the EMU to the Avionics tray on the pilot side next to the transponder and attached the network cable to the ACM.
I decided to move the master contractor from underneath the Avionics tray by the battery to the top surface on the co-pilots side which will allow room to mount the starter contactor directly next to it.

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Nov 14, 2023 ADAHRS - (1 hour) Category: Avionics

Started fabrication of bracket to level the ADAHRS unit.

Nov 10, 2023 aircraft rear harness - (2 hours) Category: Avionics

Started wiring the rear harness . Took the GPS input wire from the ELT and connected it into the Dsub connector . Then connected two pins into one wire for each of the wing landing lights. Two 20 gage to one 18 gage and terminated the wire in the wing root area..

Nov 09, 2023 ADS-B wiring redo - (4 hours)

Category: Avionics

I had to redo the ADS-B signal wires, seems they need to be a twisted pair. So I removed all the wire lacing and pulled the two out leaving the power and ground. Then I threaded the two new wires and secured them again. I then landed them in the Transponder/ADS-B/GPS DSUB going into the ACM.
I took the three wire shielded coming from the ELT and landed two of the wires(white/greenwhite) in the cockpit control with the supplied molex connector . The blue/white serial GPS input RX will have to be routed to the rear aircraft connector at the ACM.

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Nov 08, 2023 Co-pilot control stick wiring - (3 hours)

Category: Avionics

Finished up wiring the co-pilot control stick PTT.

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Nov 07, 2023 Intercom & Control sticks - (5 hours) Category: Avionics

Finished up routing the intercom wiring back to the ACM.
Put snakeskin on the control sticks wiring loom and routed them to the base of the front seats. Completed wiring the pilot side.