| __Date___ | Hrs | |
| 01-Jan-00 | Painted the battery box assembly, the roll-over bar & the forward floor pieces. All done with the gray Valspar enamel. Re-soldered the elevator trim connector mounted on the aft deck. Crimped an RJ-11 connector onto the ELT cable & retested the ELT. Installed the OAT sensor in the left NACA duct using JB Weld. Mounted the red warning light above the EIS-4000. | 6 |
| 02-Jan-00 | Removed nose gear leg & wheel & primed with Tempo zinc oxide. Wired the OAT sensor to the EIS-4000. Put foam in a dixie cup around the OAT sensor to insulate from cabin temperature. Removed front crankshaft plug & pierced rear plug per Lycoming AD for fixed pitch prop. Installed a new front plug, sealing with high temp Permatex gasket maker & hitting with a hammer & socket to flatten & expand the plug into place. Finished tidying up the cabling to the tail. | 4 |
| 03-Jan-00 | Sprayed the nose wheel with white top coat. Wired from the ignition switch terminals through 33K resistors to a selector switch & then to the EIS-4000 tach input. Checked the left mag timing - spot on 25 deg with the impulse coupling kicking in at TDC. Set the right mag timing to match the left at 25 deg - this mag had to be moved 19-Jul-99 to install an oil cooler fitting. Added a squirt of Aeroshell 2F preserving fluid to each cylinder, then topped the engine up with the rest of the gallon through the oil filler. Installed dehydrating plugs in the top spark plug holes. | 4 |
| 04-Jan-00 | Final assembly of the nose gear leg & wheel. Torqued the axle bolt to 7 ft/lbs. Tightened the leg bottom nut to achieve sideways breakout force of 22 lbs at the axle (11 lbs with lever doubling the force). Mounted the spacer & rear spinner plate to the propeller. Mounted the propeller assembly to the crankshaft flange, after installing the alternator drive belt. Confirmed spinner fit & propeller tracking. Lengthened the slot on the air scoop by 4 inches. Needs to be even longer to allow lower cowl mounting with propeller installed. | 6 |
| 05-Jan-00 | Lengthened slot in air scoop so that the lower cowl will fit behind the spinner. Rechecked 62 ft/lb prop bolt torque & safety wired the bolts with .041 wire. | 2 |
| 06-Jan-00 | Tightened the engine oil & fuel hose couplings (except the fuel line to the carb - need to do a fuel flow test). Also tightened the brake line couplings. Put orange seal on all tightened connections. Safety wired the fuel filler tube. Blocked off the 1/2" hole in the firewall box (throttle cable attempt) with SS firewall material riveted together & red RTV. | 2 |
| 08-Jan-00 | Dave Paulus, Chapter 1158 Glastar builder, visited to look at engine installation. Added tie wrap cradle bases to tidy up the wiring. Finished making up the battery cables & made the battery box hinge pins. | 4 |
| 09-Jan-00 | More wiring tidy up. Riveted on the 6110 forward deck pieces. Mounted the roll-over bar. Riveted the top of the oil separator drain reservoir to the bracket & tapped it 1/8" NPT to take a hose fitting. | 12 |
| 10-Jan-00 | Installed ground wires for com1 & com2 & Navaid A/P (3 x 16 awg), transponder & altitude encoder (2 x 18awg). Installed lighting dimmer wires for radio stack (2 x 22awg). Installed wires for defrost fans (2 x 18awg). Prepared forward top skin for dimpling - removed plastic & deburred. Deburred & dimpled the underlying structure for the skin. | 3.5 |
| 11-Jan-00 | Dimpled the forward top skin. Primed the skin & the oil cooler door assembly with SW wash primer. | 3 |
| 13-Jan-00 | Ordered 5 point harnesses from Pacific Aero Harnesses. Installed the Matco reservoir for the oil drain from the air/oil separator. Finished tidying wiring in the forward fuselage bay, using a combination of tie wraps & waxed lace ties. | 3 |
| 14-Jan-00 | Cut the bulkhead behind the instrument panel to allow for radios longer than 8.5 inches. Looks like I need to use the Garmin GTX320 transponder at the bottom of the stack (8.25"). Added a piece of .040 angle to reinforce cut away area. Started mounting the .063 angles for radio support. | 3.5 |
| 15-Jan-00 | Further work on the radio bracket support. Countersunk & primed the upper cowl hinge, ready to mount on the firewall with the top skin. Riveted the forward top skin, using a bead of high temp RTV on the firewall joint. | 12.5 |
| 16-Jan-00 | Squeezed the rivets on the firewall edge of the forward top skin. Replaced the fresh air vents (removed for riveting the skin). Checked the fit of the intrument panel structure & modified accordingly. | 6.5 |
| 17-Jan-00 | Riveted & fitted the oil cooler door, safetying the hinge pin with .032 safety wire. Added nutplates to the instrument panel for facia mounting. Cut the hole in the panel for oil cooler door control, cabin heat control, & magneto RPM select switch. | 4.5 |
| 18-Jan-00 | Further work on the radio stack mounting angles & nutplates for the radio stack facia. | 3 |
| 19-Jan-00 | Installed the MSC-34 & MSC-44 Cherry rivets at the aft end of the top skin, where we couldn't buck solid rivets into the fuselage longerons. Primed & riveted the two pairs of radio support angles. | 2 |
| 20-Jan-00 | Prepared, primed, painted & installed the panel skeleton. In theory, with #8 screws in nutplates, this assembly is removeable. I hope it never needs to come out! | 2 |
| 21-Jan-00 | Add two .040 tabs securing the leading edge of the windshield into #6 nutplates. Prepared, masked off, primed & painted both sides of the glare shield part of the forward top skin. | 3 |
| 22-Jan-00 | Mounted two 3" brushless DC fans for windshield defrost. Radio Shack 273-243B 0.16A each. Riveted .040 doubler to skin, & mounted fans with #8 screws & lock nuts, using aluminum door screen material to prevent things falling in. Drilled 1 3/16" hole halfway up the windshield brace bar, for compass lighting wire. Drilled a corresponding hole through the skin at the base of the bar. Used rubber grommets in the holes. | 5 |
| 23-Jan-00 | Painted the fan screens. Final mounted & wired the fans. Installed wiring (2x 22awg) through the windshield brace for compass lighting. Installed the brace with final AN hardware. Added .063 angle & .125 UMHW strip inside the battery box,as a vertical battery retainer, per the plans. Fitted firewall insulation material behind & under the battery tray. Installed the battery tray with final AN3-4A bolts going into the nutplates. Reinstalled the battery, torquing the terminals to 70 in/lbs. | 9 |
| 24-Jan-00 | Replaced the pan head #8 defrost fan screws with countersunk #6, dimpling through the skin & doubler. Tidied up some of the firewall wiring & hose securing points, to make sure that no further firewall holes are required before doing the firewall insulation. Installed, wired & tested the EIS-4000 warning light. Mounted the RPM mag select switch - it broke! Have to find a replacement from somewhere other than Radio Shack. | 2.5 |
| 26-Jan-00 | Added a piece of .063 angle just above the throttle/mixture cable firewall fittings, & mounted adel clamps to support EGT/CHT wiring & the fuel pressure sender hose. This would have been a lot easier befor the forward top skin was on! Did some further tidying of EGT/CHT wiring to left side of engine. | 2.5 |
| 27-Jan-00 | Installed the control cables for the oil cooler door & cabin heat. Mounted the tray for the RST audio panel. | 3.5 |
| 28-Jan-00 | Installed two adel clamps supporting the oil cooler door control cable. Mounted the windshield, securing it with cleko's. Mounted the canopy. Pop riveted the last few AACQ rivets on the forward canopy frame - ran out of rivets 18 months ago. | 3 |
| 29-Jan-00 | Marty, Paul, Jerry & Chris from Chaper 18 visited. Drilled out the windshield mounting holes to 3/16" & installed the #6 screws, with tinnerman washers, into the tapped rollover bar. Made some adjustments to the canopy latch & removed the AN960-10L washers from under the left UMHW mounting block. The aft skirt still doesn't fit very well :-( Removed the prop & replaced the Gates 7350 alternator belt, which was too tight, with a 7355. Replaced & torqued the prop bolts to 45 ft/lbs, but didn't refit the safety wire. | 3 |
| 30-Jan-00 | Installed additional MK319BS rivets, canopy side skins to canopy frames, to comply with plans spacing. Added .032 plates to pull down the aft canopy skirts. These are riveted 1" forward of the trailing skirt edge & then pop riveted to the canopy frame. | 5.5 |
| 31-Jan-00 | Ordered SL30, SL70 & encoder from Van's (2 week delivery). Ordered Skymap IIIC & rack mount from Chief (immediate & 2 week delivery). Further canopy fitting work. Pop riveted the rear hold down plates after some adjustment. There is now just one gap of just over 1/16". | 2 |
| 01-Feb-00 | Talked to Navaid Devices. Still on track for delivery around end of Feb. They will ship the servo ASAP. Confirmed requirement for Smart Coupler control panel - 3/4" x 3/4". | |
| 01-Feb-00 | Worked on fitting the cowl air inlets to the plenum, with baffle seal material. | 2.5 |
| 03-Feb-00 | Finished fitting baffle material inlets on lower cowl. Riveted the material with .032 backing strip. Checked the firewall for leaks by putting a light inside & switching all other lights off. Problems in lower corners & throttle/mixture cable eyeball fittings. Sealed all with high temperature RTV. | 3 |
| 04-Feb-00 | Riveted baffle material to upper cowl inlets. | 1.5 |
| 05-Feb-00 | Tom Willis, EAA Tech Counselor, visited for an inspection. Mounted the Com antenna using .040 backing plate & nutplates. Mounted the Nav antenna on top of the vertical stabilizer, using the technique described recently in the Rvator. | 5 |
| 06-Feb-00 | Mounted two more #4 nutplates replacing the two cut away from the VS tip for the antenna mount. Mounted the transponder antenna just aft of the firewall on the right side. Adjusted the alternator belt tension & safety wired it. Fitted insulating boots to the mag P-lead connectors & to the fuel pressure sensor terminal. Added hi temp RTV to seal various gaps between the baffling & the engine. | 3 |
| 19-Feb-00 | Used 2" fibreglass tape & West System epoxy to glass the windshield front (four staggered layers) & canopy bow (three layers - note: added one more layer Nov 00 to make total of four). Peel ply was added at the front, but was unworkable on the canopy bow - it doesn't bend sideways the way glass tape does. The overlap on the canopy plexiglass was maintained at 1/4". Electrical tape worked very well to mask off the fibre glass areas. | 8 |
| 20-Feb-00 | Released the canopy, after unlatching, by pressing on it along the bow joint, breaking the seal bit by bit. Removed all the masking & replaced with fresh electrical tape. Sanded the fibre glass, ready for filling with micro-balloon mixture. Riveted with CS4-4 pop rivets at 4" centres, per the plans. | 3 |
| 24-Feb-00 | Installed wiring in the right wing for the Navaid servo, 3 pin molex connectors at each end. Primed & riveted the servo mounting tray. Repositioned the servo crank 180 degrees from the delivered state. | 3 |
| 26-Feb-00 | Used 2" fibreglass tape & West System epoxy to reinforce the air scoop to cowl joint on the outside. Mixed epoxy & micro balloons & started filling the windshield fibreglass. Installed the Navaid servo mounting tray & the servo (#6 screws into nutplates in the tray) in the right wing. Installed the wing leveller bearing mount on the aileron bell crank. Cut the servo pushrod to size & riveted the rod bearing. Sanded the filler on the windshield fibreglass. | 8 |
| 27-Feb-00 | More micro balloon mixture on the windshield fairing & on the air scoop joint. Replaced the pitot heat wiring in the left wing, soldering the connector pins with high temperature (2% silver) solder. Final installed the pushrods from bell-crank to aileron on both wings. Jim Rodrian gave me keys to his hangar. Moved the Craftsman tool storage units into the hangar. Filled out aircraft registration paperwork - needs a Notary. | 5 |
| 28-Feb-00 | Had the ownership affidavit notarized for the registration application & mailed it to FAA. Sanded the windshield fairing & removed the masking electrical tape. Sanded the airscoop joint. | 1.5 |
| 29-Feb-00 | Put a hole, with bushing, through the fuselage in the wing root area about 12" aft of the main spar, each side, to take the lighting, pitot heat & Navaid servo wires & connectors. Put a small hole, with vinyl grommet, between the brake line fitting & the vent tube exit, each side, to bring the fuel level sender wires through the fuselage forward of the main spar. Navaid turn coordinator head arrived, so wired the connector for that - no wiring for SL30 or Skymap connection to A/P yet. | 2.5 |
| 01-Mar-00 | Pulled out the Navaid servo for setup & test. Found that one of the #6 mounting screws had sheared! Pulled the mounting tray & replaced the #6 nutplates with #8. Connected the servo to the T/C control unit & set the null point by moving the gear wheel on the feedback pot. Determined that the direction of rotation was correct. Command a left turn - servo crank pushes towards bell crank - bellcrank pushes aileron pushrod out - right aileron lowers - right wing goes up - airplane turns left. Replaced the tray & servo. | 3 |
| 02-Mar-00 | Cut the mounting holes in the instrument panel for the Porcine GPS to A/P coupler & for the ELT control module. Made a couple of blanking plates for the two 3 1/8" instrument holes to the left of the radio stack. Made a further cut into the bulkhead behind the instrument panel to accomodate the SL70 transponder. | 3 |
| 03-Mar-00 | Tidied & secured the wriring under the seat floors. Prepared for the move to the airport | 3 |
| 04-Mar-00 | Further cut into the bulkhead behind the panel & riveted a piece of .063 angle to reinforce the cut-out. Moved the fuselage & wings to Jim Rodrian's hangar at West Bend Airport, with the help of Marty Pavlovich & Keith Brue. | 22 |
| 05-Mar-00 | Moved more parts & tools to the airport. Started mounting the empennage. Supported the fuselage on a steel cradle so that the false spar could be removed. Did initial fitting of the wings. Got a few h/w store bolts installed. | 8 |
| 07-Mar-00 | Rounded off some more h/w store bolts (3/8", 1/4", 3/16") & managed to install several more in the wing spar splice plate area. These don't go in very easily! Enough bolts are in so that the wings feel secure, with no movement discernable at the main spar. Initial alignment checking, with four plumb bobs hung over the leading edges, showed the wings exactly in a straight line with the rear spar ends fully seated. With the airplane levelled, so that each wing tip is the same height off the floor, there is 1/8" difference in the heights of the HS tips from the floor. Initial angle of incidence check indicates that the rear spar need to be pushed down into the attach structure - it rides about 3/8" high with no pressure. | 6 |
| 08-Mar-00 | Put some more bolts in the main spar. Further alignment checking is showing a slight forward sweep that needs to be dealt with. | 3 |
| 09-Mar-00 | Further wing alignment work - this has to be right! Notched the rear spar ends, per the plans, so that the wings can be swept back a little. The spacer in the rear spar carry through fork does not appear to be interfering at the moment. | 3 |
| 10-Mar-00 | Further wing alignment work. | 2 |
| 11-Mar-00 | Drilled the rear wing spar attach holes (3/16" now, eventually 5/16"). Drilled the bottom fuselage skin overlap to the wings, for nutplates. Trimmed & fitted the right wing fairing, & drilled it to the wing for nutplates. | 7 |
| 12-Mar-00 | Trimmed & fitted the left wing fairing, & drilled it to the wing for nutplates. Pulled the wings out about a foot. Installed 72 nutplates. Trimmed the rear spar attach structure to avoid interference. Flared the fuel vent lines. Refitted the wings, connecting the wing electrics & testing lights & pitot heat. Found that both wings need further rear spar attach trimming! Pulled the wings again, trimmed & replaced. This time they fit OK. | 19 |
| 13-Mar-00 | Started fitting the final AN3 & AN4 bolts for spar & gear mount attachment. Ordered .2490 & .3740 straight reams, from Avery Tools, for the NAS bolts. | 5 |
| 14-Mar-00 | Added more bolts to the landing gear mounts. Installed & connected the heated pitot tube. | 3 |
| 18-Mar-00 | Used straight reams, .2490 & .3740, turned by hand, & installed most of the NAS bolts through the wing spar splice plates. The 3/8" bolts needed a standard washer under the head, with one standard & one thin washer under the nut. | 7 |
| 19-Mar-00 | Finished reaming the 3/8" bolts in the wing spar splice. Used a 3/8" OD brass tube to drill through the four holes attaching the fuel selector mount. Drilled the two floor angle support brackets. Worked on the fuel tank attach angles & their internal support structures. | 8 |
| 20-Mar-00 | Finished the fuel tank to fuselage attach structure & primed it. Fitted & flared the fuel line from the right tank to the selector. | 4 |
| 21-Mar-00 | Installed a few more of the AN3 wing spar bolts. Installed the fuel tank attach brackets. Fitted & flared the fuel line from the left tank to the selector. | 4 |
| 22-Mar-00 | Added .063 shims at forward HS spar attach points to correct HS angle of incidence. Final mounting & torquing of HS & VS. Crimped the BNC connector onto the aft end of the nav antenna RG58 cable, ran the cable up the VS, & connected to the nav antenna hub. | 3 |
| 23-Mar-00 | Drilled the rear wing spar mounts to 5/16", torqued the AN5 castle nut to 140 in/lbs, & installed the cotter pins. Installed the fuel tank attach AN4 bolts & torqued to 50 in/lbs. Installed the elevators - they are not perfectly free moving, so need further checking. | 4 |
| 25-Mar-00 | Installed a few more wing spar bolts. Installed the fuel selector assembly & the fuel lines from the selector to the electric pump & wing tanks. Removed the lower spark plugs & spun the engine with the starter. Achieved 30+ psi oil pressure. Installed the 1/4" Al brake lines along the main gear legs. Pumped brake fluid up from each side's bleed fitting. Sat in plane and tested brakes! There was a minor weep at one of the connections, soon resolved - it wasn't very tight. Disconnected the fuel line at the carb. Put some 100LL in each tank & ran fuel flow tests in level attitude with the electric pump. Running from each tank, 1/2 gal took 58-62 seconds with the EIS-4000 fuel flow gauge showing 29 gals/hour. Reconnected the fuel line at the carb & pressurised the system with the electric pump. Fuel pressure indicated at 3.0 psi. No apparent leaks. Drilled the main wheel axles & installed cotter pins through the wheel nuts. Safety wired the brake shoe bolts both sides. | 13 |
| 26-Mar-00 | Wired the selector switch from the mag P-leads to the tach input on the EIS-4000. Cleaned the lower spark plugs in 100LL & reinstalled them. Removed the fuselage support cradle, rolled the aircraft outside, set chocks, tied it down, set brakes & started the engine! Keith Brue & Dale acted as safety officers with fire extinguishers. The engine ran fine. No RPM indication & the oil temperature never moved from 59 deg F. Oil & fuel pressure, CHT & EGT, voltage, & fuel flow indications were all satisfactory. Ran for about 10 minutes, checked mags. Mixture idle cut-off did not stop the engine. Switching off the mags did. Checked for oil & fuel leaks. Started up again, ran for a couple of minutes, then took it up to full throttle for 10 secs. Shut down, rechecked everything. Decided to taxi it 50 yds - no problem, except for extremely noisy brakes. Found a slight leak on the right brake cylinder fitting. Removed the oil temperature sensor. It had oil on it. Heated with hot air gun & got a temperatur | 4 |
| 30-Mar-00 | Found that the tach wire was pulled out of the connector on the back of the EIS-4000. Soldered the pin. Also tested the serial logging output, running Greg's Qbasic program on an HP 95LX. Started work on the radio rack mounting structure. Drilled a couple of holes to locate the SL30 & SL70. Added horizontal .062 angles to attach the Skymap IIIC rack mount unit. | 3 |
| 31-Mar-00 | More work on the radio rack mounting structure. Put the new chip into the EIS-4000. Now it reads voltage at 16.9 - need to call Gregg! | 3 |
| 02-Apr-00 | More work on the radio rack mounting structure. Used JB Weld to secure .062 spacers to the top of the transponder mounting tray to separate it from the Nav/Com. Started mounting the flaps, trimming the inboard ends to match the fuselage. The left flap is OK, but the right flap actuating bracket interferes with the fuselage. Solution is to replace the hinge, moving the flap outboard 3/16" or so. | 6 |
| 03-Apr-00 | Greg told me about a setting on the EIS-4000 to correct the high voltage reading - change HGF to NGF. Made up the com antenna cable for the SL30. Wired power & ground for com & nav sections of SL30. It powers up & displays stuff!. Drilled a hole near the electric fuel boost pump for the Tygon pitot line. Brought it through a rubber grommet. | 3.5 |
| 05-Apr-00 | Mounted the com antenna. Worked on SL-30 nav/com wiring. Resolved problem with co-pilot microphone jack. Connected nav antenna & audio. Tested com & nav sections. | 4 |
| 06-Apr-00 | Mounted the altitude encoder on the bulkhead behind the EIS-4000. Wired the SL-70 transponder & encoder and tested both. | 3.5 |
| 08-Apr-00 | Wired the Skymap III rack mount unit & tested the NMEA serial output to the Porcine coupler on the Navaid A/P. Cut the facia panel for the radio stack. Tidied up some of the wiring runs. Made the four steel rudder cable links to the pedals. Prepared & primed the steel links, the GPS mounting angles & the backs of the facia panels. | 10 |
| 09-Apr-00 | Riveted the mounting angles for the GPS. Ran a radio check: "West Bend Unicom, Experimental eight six charlie golf requests radio check." "Experimental calling West Bend, reading you loud & clear." Put the flap control mechanism in place & cut the odd shaped hole in the fuselage for the control rod on the left flap. Found that the control rod, made to the 3 1/2" plans length 8-Apr-98, was too short! I could make it work with two threads engaged on each rod end. Ordered more Al tubing to make new pushrods. Drilled out about 48 rivets to remove the hinge on the right flap, so that it can be moved outboard with a new hinge. Inserted the aileron pushrods through the wingtips & determined the exact length (58" length on the tube only). Installed each rod end with the prescribed 6 MD42BS pop rivets. Primed & painted the aileron pushrods. Primed & painted the instrument facia panel - one coat SW primer, two coats Valspar gray enamel. | 10 |
| 10-Apr-00 | Temporarily refitted the old hinge so that the right flap is 3/16" further outboard. Cut the control rod hole in the fuselage & trimmed the flap to fit. Trimmed 1/8" off the outboard end of the flap to maintain distance from the aileron (1/16" will come off the aileron later). Sanded the chipped paint off the control weldment that the sticks, elevator & ailerons connect to, primed & painted it. | 5 |
| 11-Apr-00 | Installed & torqued the last eight AN3 bolts in the main wing spar. Installed the #8 screws in the bottom wing to fuselage overlap on each side. | 2 |
| 12-Apr-00 | Retorqued the prop bolts, installed .041 safety wire & mounted the spinner. Installed the last two landing gear mount bolts on the left side. | 2 |
| 13-Apr-00 | Applied the "EXPERIMENTAL" decal to the baggage bulkhead. Printed & applied the necessary labels to the instrument panel facia. | 1 |
| 14-Apr-00 | Mounted an RJ-11 jack for the EIS-4000 engine monitor serial logging output. Mounted all the instruments in the instrument panel facia plate. The AH now has a diagonal crack in the glass - arrgh! I don't know how it happened. Painted the inside of the top & bottom cowls with high temperature silver Rustoleum paint. This was due to a tip from Larry Vetterman at the Red Wing RV Forum, who said that the prepreg epoxy cowls were particularly susceptible to delamination through heat soaking. | 3 |
| 15-Apr-00 | Installed the Gretz Aero GPS antenna on the glare shield. Connected the compass lighting wires to ground & the lamp dimmer circuit. Wired the EIS-4000 serial logging output to the RJ-11 jack. Torqued & safety wired the brake caliper bolts on the right wheel. Note: the brake shoes are the riveted type. Finished tidying up the wiring to the right of the radio stack. Installed the SL-70 & SL-30 trays & connectors. Applied the N86CG decals to either side of the vertical stabiliser. Installed the last two landing gear mount bolts on the right side. Glassed in 3/16" balsa wood plugs with bidirectional cloth to close the forward ends of the elevator counter balance arms. Fitted #8 nutplates to secure the forward ends of the cowling hinges, using single hinge eyes. Put screws in the plenum chamber cover, in preparation for taxi tests. Tidied the firewall forward wiring. Painted the cabin air vent surrounds - somehow, these were still in primer. Adjusted the idle mixture screw one full turn clockwise (le | 12 |
| 16-Apr-00 | More wiring tidy up. Mounted the ELT antenna under the empennage fairing with .062 bracket on the aft bulkhead. Started installing the Orndorff supplied firewall insulation. Glassed a layer of bidirectional cloth on the outside of the elevator arms. | 9 |
| 17-Apr-00 | Finished the firewall insulation. Adjusted the voltage regulator fully counter-clockwise - the charging voltage on the first engine run was 14.6 rather than the recommended 14.1 volts. Re-installed the air vents, using black brass screws. Moved the SL-30 tray back 1/16" so that the front plate is even with the SL-70. Installed the right panel assembly with the EIS-4000 & screwed on the connectors. Installed the SkyMap IIIC with the rack-mount unit. | 3.5 |
| 21-Apr-00 | Installed AN4-14A bolt in the main elevator bearing, 2 1/2 washers to right of bearing, 2 to the left. Torqued nut to 50 in/lbs. Drilled new hinge to the right flap, moving the flap outboard 3/16". Deburred & primed hinge. | 2 |
| 22-Apr-00 | Installed the elevator & aileron pushrods, along with the control stick assemblies. Riveted the new hinge to the right flap. Installed the wing tips. Installed the ailerons. | 12 |
| 23-Apr-00 | Trimmed the rib that was interfering with the AH. Installed the rest of the instrument panel & connected pitot - static still to cabin. Installed the control system hardware. Made new flap pushrods & fitted the flaps. Tom spent most of the day fitting the wing to fuselage fairing strips. Installed the pilot side harness & seat. Installed the canopy & cowl. Did taxi test. Bedded in the brakes with two hard braking stops from 30 knots. Took the speed to 40 knots & raised the nose wheel. No control problems noted. Analysed the engine monitor log - no fuel flow recorded. | 22 |
| Notes on the engine log: First RPM increase to 1700 was run-up with mag check. The blip to zero RPM during the run-up was the mag check & switching RPM inputs. The next double peak was the brake bedding procedure - two hard stops from ~30 kts. Then everything went to zero because the engine stopped - idle not adjusted correctly. Then another peak to ~1700 RPM for taxi test at ~40 kts, lifting the nose wheel. Repeated the 40 kt taxi test then engine stopped again. The voltage reading showed no charging - regulator needs adjusting. The fuel flow was zero - no calibration parameter set. The CHT spread from 340 (cyl 1) to 440 (cyl 3) indicates that some baffling changes may be required - needs watching on first flight. | 0 | |
| 27-Apr-00 | Removed flaps. Applied UMHW tape to the curved leading edges of the flaps. Used metal locknuts (smaller) to secure the push rod bearing in each flap root. Made & installed new flap hinge pins & secured with .041 safety wire through a hole in the flap brace. | 3 |
| 28-Apr-00 | Drilled out the rivets to remove the rudder stops. Made new stops, from 1/8" angle, so that they an be mounted 3/16" higher to avoid interference with the rudder control cables. Primed the inside surface of each stop. Primed & painted the flap control rods. Packed up the trailer ready to return to Marty. | 3 |
| 29-Apr-00 | Returned the trailer to Marty at Waukesha Airport. Riveted the new rudder control stops & installed the rudder with final hardware. Made a new hinge pin for the trim tab & safetied it with .041 wire. Pop riveted the baggage area floors & side panels in place. | 5 |
| 30-Apr-00 | Pop riveted the seat floors. EAA Chapter 18 technical counselor, Fred Keip, visited & did a thorough inspection.. Only concerns were spinner to prop clearance, & exhaust pipe to fuselage clearance. Installed an additional nutplate at the aft end of each wing to fuselage fairing. Installed the flap control pushrods. Adjusted the volatage regulator about 1/3 turn clockwise from the stop. Adjusted the idle mixture 1/2 turn counter clockwise (richer). | 4 |
| 03-May-00 | Adjusted aileron to bell crank pushrods out two turns to give additional 2 deg down movement to meet the spec. Adjusted aileron bell crank to control stick pushrods to level the ailerons when elevator is level. Used final hardware to install & adjust flap control mechanism. | 3.5 |
| 04-May-00 | Fabricated the top flap fairings from .032 stiffener angle. Installed the floor sections covering the elevator pushrod, along with the electric flap support structure. Need to check the "up" flap position for binding. Riveted the ID plate to the fuselage under the HS. Installed adel clamps to support the fuel lines coming from the fuel selector. Replaced the bolt in the canopy latch with final h/w. | 3.5 |
| 12-May-00 | Fabricated a bracket from .032 Al to mount the SIRS compass to the windshield brace. Tapped a 6-32 hole in the SS brace bar for a brass screw to locate the bracket. Installed a two pin molex connector for the compass light. Made some further adjustments to the flap control mechanism. | 2.5 |
| 13-May-00 | Finished mounting the compass. Installed the replacement artificial horizon. Secured the brake lines to the gear legs with tubing & tie-wraps. Dimpled & primed the upper flap fairings. | 2 |
| 14-May-00 | Riveted the upper flap fairings. Temporarily installed the interior & drained the fuel tanks. Weighed the aircraft using the scales from EAA Chapter 18. Ground attitude: L 412, R 406, N 252. Flight attitude: L 394, R 388, N 284 for a total empty weight of 1068, without gear leg fairings & wheel pants (or paint). Tom checked the control surface deflections: ailerons up/down 27/15, elevator 27/22.5, rudder 32 L/R, flaps 43 down. Did another 15 minute engine run. Charging voltage was 12.6. The mixture control seems to have no effect. Full throttle static RPM was 2200. | 10.5 |
| 24-May-00 | Removed the carburetor to check the idle cut-off mechanism. On removing the fuel bowl, found that the mixture control tube was probably not correctly located at the bottom of the bowl. There's a slot in the tube that rotates to line up with a slot in the cup at the base of the bowl. For idle cut-off to occur, that opening needs to close. If the tube is not in the cup, it will have full fuel flow however the mixture control is positioned. Re-assembled & re-installed the carburetor. Adjusted the idle mixture 1/2 turn counter clockwise (richer), i.e. back to the original setting before I started fiddling with it!. | 2 |
| 25-May-00 | Removed the left instrument panel & then removed the vacuum gyros from the panel so that they can be connected to the vacuum system. Used an alternate hole on the AH for the vacuum line - the standard hole at the top caused interference with aircraft structure. Used Tygon tubing to connect to the altitude encoder. Using gentle suction, discovered that the encoder leaks - further investigation later. | 2.5 |
| 25-May-00 | Tightened the static connection on the altitude encoder. Completed the vacuum instrument installation & reinstalled the panel making the static & pitot connections. Made a 10 minute engine test. Vacuum suction in the green, charging voltage at 14.5, idle RPM ~700. The CHT & EGT readings for cylinder 1 were not working - later found that the connector wasn't fully seated at the back of the EIS-4000. Screwed the connector in properly. The idle cut-off now works! | 2.5 |
| 26-May-00 | Used two turns of .032 safety wire to secure each end of each piece of fire-sleeve on the fuel lines forward of the firewall. Installed the velcro strips that are used to attach the seat bottoms & backs. Mounted the harnesses & torqued the AN4 nuts. | 2 |
| 27-May-00 | Finally sealed the static connection to the altitude encoder with PTFE pipe sealant. Installed the alternate static air valve & tested the static system for leakage - no apparent leakage. Fitted the control stick boots. Sealed the firewall wiring grommets with red RTV. | 6 |
| 28-May-00 | Installed the cabin floor insulation & carpet. | 3 |
| 01-Jun-00 | Did differential compression tests on cold engine: 1= 75/80; 2= 75/80; 3= 68/80; 4= 71/80 | 2 |
| 02-Jun-00 | Armed ELT & tested panel switch & reset at 11:01am monitoring 121.5 on Icom hand-held. Added labels for alt static & EIS-4000 RS-232. | 1 |
| 02-Jun-00 | Tom Willis, the DAR, came to do the final inspection, taking about three hours. There were only a few minor issues. The most significant was the lack of safety wire on the four screws attaching the gascolator bowl - I hadn't noticed the screws were drilled for wire! Finally, after nearly three years & 2100 hours, I have the airworthiness certificate. | 3 |
| 2107 |