Apr 27, 2024     Week 45 - (15 hours)       Category: Controls

This week began with reinstalling the yoke chain and tensioning it properly. The newly painted instrument panel was then installed, making further work on the yoke more difficult. Still we managed to get cotter pins installed on the turnbuckle clevis bolts. However, they still need to be safety wired. Further work had to be put on hold as the fuselage was loaded onto a trailer for transport to Laurel Avionics in Johnstown Pennsylvania. Arrangements have been made with them to install our transponder, radio, and two AV30c instruments along with some other electrical work. The same day our newly overhauled O-200 engine arrived from the shop. Things are moving along.

  Apr 13, 2024     Week 44 - (15 hours)       Category: Controls

This week we installed more trim pulleys and worked on the control yoke chain and related parts. Working aft, we installed the two pairs of trim pulleys that run just under the cabin floor. The parts manual calls for another pair at the aft end of the baggage compartment. The maintenance manual does not call for this set and there is no bracket for it. That, plus the fact that we only have 12 pulleys rather than the 14 shown in the parts manual, has led us to conclude the parts manual is wrong or might be referencing an earlier model. We looked at hooking up the new trim chain to the new cables, but it seems we may need a special tool to do that, so we set it aside for now. We then got into the complex control yoke chain and sprocket system. It needed cleaning and upon inspection by one of our A&Ps a couple of issues were found. The safety wires on both turnbuckles were the wrong size and two of the clevis bolts with castle nuts lacked cotter pins. So we ended up taking a lot of it apart and cleaning everything. Complete reassembly will happen next time.

  Apr 08, 2024     Week 43 - (20 hours)       Category: Controls

The trim system was the main focus this week. Four trim pulleys are mounted against the firewall and so need to go in before installing the rudder pedals. In order to install the pulleys we had to also install the new forward trim cables. We first employed one of our younger members to crawl into the rear fuselage. While he was in there we had him vacuum out some debris in the tail cone. His main mission, however, was to retrieve the forward trim cables that were under the floorboards. Once that was done we attached the end of each old cable to the forward end of each new cable and then threaded them through. Next, one of our members crawled under the panel to install the sets of pulleys with their respective cables. Not an easy task. The next job will be to complete the installation by installing the sets of pulleys that bring the new forward cables under the floorboards back to where they will eventually be connected to the two rear trim cables.

  Apr 02, 2024     Week 42 - (20 hours)       Category: Controls

Figuring out puzzles continued this week. More work was done cleaning and laying out the complex rudder pedal assembly. Robert continued sorting out wires and connectors, some of which lack a clear indication of what they do. Work also continued on things on or near the interior firewall that need to go in before the rudder pedals can be installed. The parking brake was reconnected. Because four trim pulleys need to be mounted against the firewall, we started figuring out the trim system and its cables. We will be installing new cables.

  Mar 23, 2024     Week 41 - (30 hours)       Category: Landing Gear

The Rans is nearly finished, so attention returned to the Cessna this week. A recently discovered AD on the ignition switch resulted in its removal. A new one is on order. The large upper snap rings were installed on the main gear legs. The new Cleveland brakes and wheels were installed and fluid was temporarily added to the nose gear strut to keep it from bottoming out. Then the plane was lowered onto its gear with a cushioned sawhorse supporting the tail. That done, we could once again get into the interior to continue work there. We recruited one of our younger members to crawl under the panel to install the brake master cylinders and hoses. The rudder pedals will soon go in, so a few members began the process of figuring out that puzzle.

  Mar 09, 2024     Week 40 - (30 hours)       Category: Tail Feathers

While the Rans continued to demand attention, some signifiant progress has nonetheless been made on the Cessna in the last couple of weeks. The wings, tail feathers, and some other parts were sent to the paint shop in Pennsylvania. We also started installing insulation between the panel and the firewall. We are using 3M 4014 Sound Dampening panels. They are self adhesive and go under the glare shield and along the sides of the boot cowl area. More will go inside the wing root area and inside the doors. Another on-going project is the electrical system. New solenoids were installed on the firewall and battery box. After much trial and error, the new STC gascolator was also finally secured in place. Finally, this weekend the process of getting the Cessna back on its gear was begun. With some effort, the main gear legs are mostly installed. The large snap rings on the upper legs are awaiting a different tool to install. Meanwhile, the nose gear was bolted in place and work was begun on installing the new Cleveland brakes. She should be finally sitting on her own gear soon.

  Feb 17, 2024     Week 39 - (15 hours)       Category: Tail Feathers

Work continues on the Rans S-12XL, but we still made some progress on the Cessna. Our A&P/IA returned with the right rivets and completed installation of the bracket on the horizontal stabilizer. The brake master cylinders were also cleaned and overhauled with new O-rings and seals. They're ready to reinstall. The process of installing new insulation has also begun but I didn't get any photos of that. On Monday 2/19 the plan is to send the wings and some other parts to Pennsylvania for paint.

  Feb 10, 2024     Week 38 - (20 hours)       Category: Wings

Once again the Rans S-12XL took some of our attention, but that project is nearing completion and will soon be ready for our A&P/IA to complete the condition inspection. Meanwhile, some progress was made on the horizontal stabilizer bracket. Our A&P returned with a stronger rivet gun and did a few rivets, but found that some of the holes required bigger rivets than we had on hand. He'll be back. Tires and tubes were also mounted on the new Cleveland wheels. And the overhauled nose gear was mostly assembled. Robert also continues to look at various systems to see what we need in terms of electrical stuff.

  Feb 03, 2024     Week 37 - (20 hours)       Category: Wings

A very busy week. At one point on Saturday we had three projects going at once in the hangar. The Rans S-12XL continues to demand some of our attention, but we still managed to accomplish some important things on the Cessna. Our A&P/IA came to look at our stabilizer bracket issue. He determined that the problem was our rivet gun wasn't powerful enough. He will return with a different rivet gun to finish the job at some point. In the meantime, we continued to work toward getting the plane on its gear and getting wings ready for paint. A part on the nose gear was lightly machined to make it round to fit and the gear was mostly assembled with all new O-rings and hardware. We decided to replace the old gascolator assembly with a new and better “Steves Gascolator” STC. We ran into a problem in that the bracket that adapts the new gascolator to the Cessna's firewall fitting doesn't fit. We've been in communication with the manufacturer, but they've been little help. Stay tuned on that one. In order to send the wings up to get painted, we decided it would be best to fit and drill the new Horner wingtips in advance so that we don't scratch new paint later. We also got new tips for all of the tail surfaces so some of them were fitted as well.

  Jan 20, 2024     Week 36 - (15 hours)       Category: Tail Feathers

Not too much has been done on the Cessna the last couple of weeks. That's because we needed to bring in the donated Rans S-12XL to begin changing out hoses in preparation for its condition inspection. But a few things got done. Parts were gathered and inventoried for the nose gear rebuild and installation. On the firewall, the auxiliary power plug and fuse set were installed. The task of re-riveting the attach bracket on the rear spar of the horizontal stabilizer was begun. This is part of complying with AD80-11-04, Service bulletin SE79-49. Bucking the rivets proved difficult and hard on the arms. More to be done on that.