Mar 27, 2024     Flap Assembly - (2 hours) Category: Controls

Removed the bolts holding the flap assembly in place. Then I was able to access the ends so that I could connect the short rods that connect the flap assembly to the flaps. With the flap asssembly in place, you can't get the bolt in. I was able to attach the short rods. Next, I had to make the holes in the bottom/side of the fuselage that the rods go out of. Now I just need to resecure everything.

  Jul 03, 2023     Rudder Cables - (2 hours)       Category: Controls

Routed the rudder cables up to the rudder pedals. Set up the Rudder links.

  Apr 25, 2023     Shunt/ANL connection - (3 hours)       Category: Controls

Used copper bars to connect the shunts and ANL. Have to do one more connection from the bottom ANL to the 4AWG wire going forward to the main distribution panel. Sized the bar, drilled holes and then put heat shrink on the bar in the exposed areas.

  Dec 21, 2022     Flap Push Rods - (6 hours)       Category: Controls

Fabricated the flap pushrods. The ends had to be tapped and rod end bearings installed. Not as easy as it sounds.

  Dec 21, 2022     Aft Elevator Push Rod - (2 hours) Category: Controls

Took the Aft Elevator Push Rod in place in the fuselage and connected it to the Elevator Bellcrank. With that in place, I was able to reinstall the Flap Actuator back in the fuselage.

  Dec 19, 2022     Aft Elevator Pushrod - (2 hours)       Category: Controls

Placed the pushrod and torqued the fasteners

  Dec 10, 2022     Elevator Push Rod / Control Sticks - (6 hours)       Category: Controls

Torqued the fasteners for the control sticks.
Placed the elevator pushrod. Had to bend the rod to get it to go into the channel that is there for it. Touched up the paint.
All connections made and torqued.

  Dec 10, 2022     Elevator Push Rods - (6 hours) Category: Controls

Torqued the fasteners for the control sticks. Tried placing the the forward elevator push rod - it doesn't fit! Realized it has to bend slightly during installation and so I was able to get it installed. Some slight scratching and paint scraping. Sanded the scratches out, reprised and repainted in place. Connected the rod ends - one to the control stick weldment, and the other to the bell crank. Torqued all nuts as appropriate. Now I need to install the rear elevator pushrod.

  Dec 10, 2022     Flap Push Rods - (4 hours) Category: Controls

Fabricated the Flap Push Rods. Cut them to length, drilled the ends to size and then tapped the ends for the rod ends.

  Dec 09, 2022     Elevator Push Rod / Control Sticks3 - (3 hours) Category: Controls

Mounted rod-end on elevator pushrod. Painted and ready for installation.
Mounted the control sticks.

  Dec 09, 2022     Elevator push rod - (3 hours) Category: Controls

Received the rod ends from Vans. They were missing for the forward elevator pushrod. Mounted the control sticks.

  Nov 23, 2022     Pitch Servo - (4 hours)       Category: Controls

Mounted the GSA 28 pitch servo to the fuselage and then connected it to the elevator bellcrank.

  Nov 19, 2022     Elevator Bellcrank - (2 hours) Category: Controls

Riveted together the F-635 Elevator Bellcrank and then painted the outside (inside had been previously painted).

  Nov 17, 2022     Elevator Bellcrank - (3 hours) Category: Controls

Riveted together the F-635 Elevator Bellcrank. I had previously painted the inside. After riveting it together, I painted the bell crank.

  Jul 17, 2022     Electric Aileron Trim - (5 hours)       Category: Controls

The electric trim bracket was completed. Tested the servo and left it at the 1/2 way point. Connected it to the control arm bracket. Placed the unit in the floor and secured it. What a pain in the butt that was - hardly any access.

  Jun 25, 2022     Auxiliary Fuel Pump Assembly - (2 hours)       Category: Controls

Started to assemble the Airflow Performance Fuel Pump and Filter assembly. Cut the floor panel that it is mounted on. When I cut the cutout in part of the shroud, I totally messed it up - will be ordering that new part from Vans (keeping them in business)

  Jun 24, 2022     Flap Assembly - (8 hours) Category: Controls

Working on putting together the flap assembly. Riveted the channel - unsatisfied. Going to order a new channel.

  Jun 20, 2022     Flap Assembly - (2 hours)       Category: Controls

Began working on the flap assembly. Got all of the support blocks drilled and ready to drill the floor for the last one.

  Jun 02, 2022     Rudder Pedals / Brake Assembly - (3 hours)       Category: Controls

Installed the brake firewall doubler. Riveted the parking brake assembly in place. Connected the hoses from the brake pedals to the firewall AN fittings. That was the last part of the brake system.
Fitted the forward skin to the fuselage and clecoed part of it in place for a test fit and to see about access panels.

  Apr 11, 2022     Rudder Pedals / Brake Assembly - (7 hours)       Category: Controls

Mounted the brake pedals with all nuts and cotter keys installed. Installed all of the 90� fittings into the brake master cylinders. Connected (but did not torque) the hoses. Will place the parking brake assembly and rivet in place.
Prepped and painted the seat panels with the piano hinge seat adjustments.
Installed the baggage hold-down ring on the co-pilot side baggage compartment side panel. Looks good - will duplicate on the pilot's side.

  Apr 06, 2022     Rudder Pedals / Brake Assembly - (2 hours)       Category: Controls

Painted all of the brake pedals. Red! Looks good.

  Apr 04, 2022     Rudder Pedals / Brake Assembly - (4 hours)       Category: Controls

Disassembled, prepped and primed the brake pedals. Riveted in the center rudder pedal support. Riveted together the parking brake bracket. Working on positioning it.

  Apr 02, 2022     Rudder Pedals / Brake Assembly - (3 hours) Category: Controls

Received new brake side plates from Vans. Drilled holes in the appropriate spots and reassembled the brake pedals. Need to disassemble and prep for paint.

  Apr 01, 2022     Rudder Pedals / Brake Assembly - (4 hours)       Category: Controls

Mounted and bolted in place the brake reservoir. Drilled lightening holes in the rudder pedal support. Deburred and ready for painting. Fabricated the brake fitting (firewall) doubler. Need to have the AN fittings to drill the holes to the final size. Prepped it for painting.
Devised and fabricated the Parking Brake assembly. I then added a cable support for the actuating cable. Disassembled, deburred, and prepped for painting.

  Mar 30, 2022     Rudder Pedals / Brake Assembly - (6 hours)       Category: Controls

Fitted the rudder pedal / brake assembly in the forward fuselage. Fitted the center rudder pedal support. Drilled the holes in the longhorns. Also fitted the brake reservoir in place. Waiting for new brake side plates to replace the ones that were drilled incorrectly. After fitting everything together - will have to dissassemble it and paint.

  Mar 20, 2022     Rudder Pedals / Brake Assembly - (2 hours) Category: Controls

Just spent a couple of hours trying to match brake pedal angles since they were off from each other when the holders were straight down (90�own). Then realized, once the angles on the brake pedals matched, the rudders were displaced. The bottoms of the rudder pedals should align - not the brake pedals.

  Mar 18, 2022     Rudder Pedals / Brake Assembly - (4 hours)       Category: Controls

Disassembled all 4 pedals. Deburred and scotchbrited all of the pieces. Reassembled and put on the rudder assembly.

  Mar 17, 2022     Rudder Pedals / Brake Assembly - (5 hours)       Category: Controls

Began working on the rudder pedal / brake assembly. Set it up and began to prepare the rudder pedals. Had to cut 4" angles and then drill and shape those. Checking on a local anodizer in Sanford. I want to do them red.

  Nov 15, 2021     Control Stick Assembly - (2 hours) Category: Controls

Finished the initial construction of the control stick assembly. Mounted WD-610 and determined the number of washers required.