| __Date___ | Hrs | |
| 01-Jan-99 | Started assembly of main landing gear. Moved the bleed nipple on one brake assembly so that both point down. Primed the steps. Began fabrication of plywood laminated false spar. | 5 |
| 02-Jan-99 | Primed the main gear legs. Continued landing gear assembly. Found that either wheel fits the left gear leg, but not the right. Spent 2 hours reducing the right gear leg diameter with emory cloth to make it fit. One of the two Allen bolts supplied has no threads! Need to call Van's for a replacement. | 6 |
| 03-Jan-99 | Glued clamped & bolted the plywood laminated false spar | 1 |
| 05-Jan-99 | Talked to Scott at Van's about a replacement Allen bolt. Painted baggage floors. They had already been primed with the SW wash primer. I scuffed with scotch-brite, cleaned with a tack cloth, then one thin coat of SW PPG 882 gray primer, then two thin coats of Valspar light gray enamel. | 1 |
| 09-Jan-99 | Painted the fuselage interior, as baggage floors above. Painted the nose gear wheel assembly. | 3 |
| 10-Jan-99 | Painted miscellaneous interior pieces. Assembled nose wheel, added grease to the bearings without filling the cavity. Torqued axle bolt to 7 ft lbs per RV-list email from Van's Scott McDaniels. Torqued the 5/16 stop ring bolt to 100 in lbs. | 4 |
| 11-Jan-99 | Finished painting the landing gear mount weldments gray. Bolted the rudder pedal assembly back in place. Marked the false spar for routing so it will slide over the nutplates on the bulkhead. | 2 |
| 13-Jan-99 | Drilled mounting holes in false spar. Set in place & added landing gear mounts with temporary h/w store bolts. Need to make the holes oversize in the false spar to facilitate fitting. | 3 |
| 24-Jan-99 | Wired both wings for nav/strobe/landing lights. Need more 16awg to complete. Broke the ceramic bulb holder for one of the AeroFlash tail lights, because the shorter case mounting screw is too long! Ordered wire & connectors from Newark & AMR. | 5 |
| 25-Jan-99 | AeroFlash is sending a ceramic replacement FOC! New control shaft arrived from RST. Cleaned the audio panel PCB with lacqer thinners to remove flux. Superglued the aluminum sleeve to the new control shaft. | 0.5 |
| 30-Jan-99 | Mounted the Harbor Freight chain hoist onto a double beam. Lifted the fuselage & installed the landing gear legs with wheels. | 5 |
| 31-Jan-99 | Fitted the replacement ceramic bulb holder in the AeroFlash unit. Fabricated & temporarily fitted the four Al brake tubes running from the flexible hoses down to the wheels. | 5 |
| 01-Feb-99 | Made & fitted the mounting structure for the electric fuel pump. | 2 |
| 02-Feb-99 | Trimmed the forward edges of the sloping seat floors to avoid interference with the landing gear mounts. | 1 |
| 04-Feb-99 | Modified the fuel selector mounting so that the seat floors can be removed without dissembling the fuel selector mount. Cut the 1" holes in the mount for grommets for the fuel lines. | 2 |
| 06-Feb-99 | Deburred & primed the fuel selector mount. | 2 |
| 11-Mar-99 | Worked on fuel lines from the fuel selector. Cut the 1" fuel line holes in the fuselage sides. | 2 |
| 12-Mar-99 | Completed the fuel line between the selector & boost pump. | 2 |
| 13-Mar-99 | Made & fitted the fuel vent tubes. Added support clamps for fuel vent lines & the rigid brake lines. Made the F-699 floor support brackets & added a piece of angle to each with a nutplate to attach support clamps for the fuel lines to the fuel selector. | 5 |
| 14-Mar-99 | Fitted black conduit for wiring & static tubing in the fuselage. Mounted two "eye-ball" lights on the left side rail & wired them through the conduit (18 awg because no 22 awg available). Mounted the ground-blocks on the fire-wall top center. Mounted the instrument light dimmer electronics. | 8 |
| 17-Mar-99 | Mounted the headphone/mic/anr power jacks behind the seats. Cut the baggage side-wall to accommodate jacks & conduit. | 1 |
| 18-Mar-99 | Mounted "eye-ball" light on right side rail. Added conduit on right side. | 3 |
| 20-Mar-99 | Cut floorboards to accommodate conduit. Fabricated a hinged structure so that the fuse blocks are accessible under the right side of the instrument panel. | 6 |
| 21-Mar-99 | Riveted steps & other miscellaneous pieces with Tom. | 5 |
| 22-Mar-99 | Rebuilt the fuse block mount to give more room for switches. Trimmed 1/16" from left end of sub-panel to remove bulge in fuselage side. Worked on sub-panel switch & control spacing. | 3 |
| 26-Mar-99 | Mounted the master contactor & wired the dimmer assembly. | 3 |
| 27-Mar-99 | Mounted all the switches on the sub-panel. Wired the right rail eyeball light & the rest of the dimmer electronics. | 9 |
| 28-Mar-99 | Added a brace (.063 angle) from the centre of the sub -panel to the firewall. Wired the fuel pump, left side headphone sockets (with ANR P/S) & flaps. | 12 |
| 29-Mar-99 | Wired the right side headset jacks. Ran wiring both sides for strobe/nav/landing/taxi lights, fuel level & heated pitot. Left side conduit is really full - I may remove the static tube. | 4 |
| 31-Mar-99 | Moved static tubing outside the wiring conduit. Wired the wing lighting & pitot heat including the switches, fuse connections & molex connectors. Used a jumper cable to test the wing lights. | 4 |
| 01-Apr-99 | Replaced the 10 fuse block main bus with a 20. Replaced the fuel pump switch with a 3 position switch for pump & primer. Figured out the cable & connectors required for all the "fat" wiring, & ordered from AAMR. | 3 |
| 03-Apr-99 | Wired 8 awg from avionics & alternate avionics switches to the diode bridge. Wired the RST audio panel connector to power, light dimmer & headset jacks. Tested the Matronics governor connected to the elevator trim servo. | 6 |
| 04-Apr-99 | Shortened control sticks to allow additional wooden grip length. Mounted HS & elevators to establish fore-aft stick movement. Mounted an aileron & measured 1.5" pushrod movement from neutral to stop. Used this to determine side to side stick movement. Cut the stick clearance holes in the floorboards. Added the pitot heat wiring, with pitot connector, to the left wing. | 7 |
| 06-Apr-99 | Called Ed Low & pulled out of the engine deal. No overhaul start date confirmed. I'll probably get a new engine from Van's! | |
| 07-Apr-99 | Ordered new engine from Van's. | |
| 08-Apr-99 | Built the fuel line from the selector to the right wing. Trimmed the fittings on the backs of the ventilation eyeballs. RTV'd & tiewrapped the duct tubing to those fittings. | 2 |
| 09-Apr-99 | Received & tested the 5A breaker for the alternator regulator circuit. Tripped the breaker with a short 6 times with a 15A fuse. A 10A fuse blew without tripping the breaker. | |
| 10-Apr-99 | RTV'd & tiewrapped the duct tubes to the NACA vents. Trimmed the forward edge of the fuselage skin & drilled/cleko'd the top cowling mounting hinge to it. | 4 |
| 11-Apr-99 | More work on the cowling mounting hinges. | 2 |
| 12-Apr-99 | Ordered rubber engine mounts etc. from Van's. Fabricated the two F-696 forward wing attach brackets from 3/16" angle. | 1 |
| 13-Apr-99 | Worked on "fat" wires. Soldering terminators on per Bob Nuckolls' instructions | 4 |
| 15-Apr-99 | More wiring. Also, removed the engine mount in preparation for final mounting. | 2 |
| 17-Apr-99 | More wiring. Cut the switch panel for the MAC elevator trim switch & indicator. Mounted the 5A alternator field breaker & wired it to the fuse block via the second contacts on the master switch. Mounted & wired a "cigarette lighter" style DC outlet. Remounted the avionics bus diode bridge so that the #8 wiring could be secured. Mounted a DC outlet jack (Radio Shack jack 274-1576A, plug 274-1573A) 5.5mm OD, 2.5mm ID. | 7 |
| 18-Apr-99 | Added .062 angle from behind the pitot heat switch to the sub panel, to stiffen the switch panel structure. | 2 |
| 21-Apr-99 | Engine arrived! | |
| 24-Apr-99 | Visited the Red Wing RV Forum with Sue & Tom. Shared dinner table with George & Becki Orndorff. | |
| 25-Apr-99 | Drilled the bottom cowl to firewall mounting hinges to the fuselage with a .020 shim per the plans. Dimpled the shim & countersunk the 1/8" hinge. Primed these pieces & the side cowl hinges, & riveted all to the firewall flange. Replaced the engine mount & torqued the 3/8" bolts to 175 in/lbs. | 4 |
| 26-Apr-99 | Added 2x4 props to support the roof beam for the engine hoist. Positioned the engine & lifted it an inch to check the hoist. | 1 |
| 27-Apr-99 | Attached the engine to the Dynafocal (type 1) mount. | 3.5 |
| 28-Apr-99 | Torqued the 7/16" engine bolts to 240 in/lbs & installed the cotter pins. Started looking at cowling fit. Need 6x 2.25" 3/4" ID PVC pipe and 6x 3" 1/2" bolts. Also 7/8" box wrench for spark plugs. | 2 |
| 30-Apr-99 | Made 2" spacers from PVC pipe. Used these with washers to position the rear spinner plate 2.25" from the crank flange. | 1 |
| 01-May-99 | Fitted & trimmed upper engine cowl with 1/8" gap to top of rear spinner plate. The gap widens towards the bottom of the spinner plate. This will reduce if the engine sags 1/4" & is usual, according to RV-list email. Drilled & cleko'd firewall hinge to upper cowl. | 5 |
| 02-May-99 | Worked on fitting the lower cowl. | 3 |
| 03-May-99 | Further lower cowl fitting. | 1 |
| 08-May-99 | Lower cowl work. Finished fitting together the upper & lower cowl pieces, including the hinge attachments. | 9 |
| 09-May-99 | Added the remainder of the lower cowl attach hinges. Trimmed the air scoop & cleko'd to lower cowl. | 6 |
| 15-May-99 | Mounted the Vetterman cross-over exhaust system. Mounted the carb & started work on the filtered air box assembly. | 6 |
| 16-May-99 | Fabricated the filtered air box alternate air assembly. | 5 |
| 17-May-99 | Primed the filtered air box assembly & painted the steel actuator. | 1 |
| 18-May-99 | Trimmed the excess fibre glass from the filtered air box. Drilled drain holes in the FAB, one inside & one outside the air filter. Riveted the assembly. Added a positive control stop for the heated air position. | 2 |
| 20-May-99 | Cleko'd the cowl inlet pieces to the cowl. Trimmed the oil filler access door & drilled the hinge. | 3 |
| 21-May-99 | Made shims for the oil door hinges (.032 on cowling, .063 on door). Squeezed rivets, hinge to door - need to buck the hinge to cowl rivets. Fitted the cam lock closures. | 2 |
| 22-May-99 | Drilled through the left main spar bulkhead just under the longeron so that wires don't need to be routed through external conduit. | 1 |
| 23-May-99 | Removed the nose gear leg for return to Van's for replacement. Used C-frame to finish riveting the oil door hinge. Cut slot in top of left main spar bulkhead for static tube to go just under longeron. Drilled right side for wiring. Started disconnecting panel side of wiring & passed through bushings on right side. Cut flats on bottoms of rail lights to match the rails. | 6.5 |
| 24-May-99 | Pulled wires through the new side rail bushings. Replaced left rail light 18 awg wiring with 22 awg. Replaced the 14 awg wire in fuselage with new wire. Added terminal strip for dimmer outputs. | 3 |
| 27-May-99 | Mike Seager gave me another 1.7 hrs instruction in the blue 6A N666RV operating out of Van's air strip. | |
| 29-May-99 | Started work on the baffling. | 2 |
| 30-May-99 | Continued baffling installation. | 9 |
| 31-May-99 | More baffling! Almost ready to start trimming the top to 1/2" from cowl. | 7 |
| 01-Jun-99 | Discovered that I'd order the wrong Sensenich prop from Van's - 4" extension instead of 2 1/4"! A phone call to Tom Green with a follow up fax straightened it out. It's not due to be delivered until August. Trimmed the baffling to 1/2" below top cowl. | 3 |
| 03-Jun-99 | Added various bracing pieces to the cowl & started mounting the oil cooler on the left back baffle. | 2.5 |
| 04-Jun-99 | Worked on oil cooler mounting. | 2 |
| 05-Jun-99 | More baffling work. Drilled out most holes for 1/8" rivets, | 3 |
| 06-Jun-99 | Miscellaneous systems work. Made spacers for the brake fittings through the fuselage & for the tank vent outlets. Refitted the Al tubing for both. Added stiffening for master solenoid mounting & set up starter solenoid back to back on firewall side. Spent a lot of time working out hose fittings etc. & put in orders to Van's (alternator kit, control cables etc) & Spruce (hose fittings, oil breather/separator etc). | 4 |
| 07-Jun-99 | Installed firewall fitting for fuel line. Fabricated 3/8" Al fuel tube from electric pump to firewall. | 2 |
| 10-Jun-99 | New nose gear leg arrived from Van's. Drilled the nose wheel stop left to right (old holes wer fore/aft) & mounted the leg & wheel assembly. Torqued the 5/16" stop collar bolt to 100 in/lbs. | 2 |
| 13-Jun-99 | Completed wiring the avionics bus alternate path. Moved the fuel line to avoid rudder pedal interference. | 2 |
| 15-Jun-99 | Finished wiring the flap control switch. Installed the brass primer restrictor fittings (AN4022-1) in the lower ports on cylinders 1,2,4, torquing to 50 in/lbs with Loctite PST (pipe sealant with teflon). | 1 |
| 19-Jun-99 | Fitted the Robbins heat muff & the carb heat muff. Installed the steel fittings for the oil cooler lines. Needed to remove the right mag to install one of the engine fittings for the oil cooler - must retime the mag befor engine start. | 4 |
| 20-Jun-99 | Wired the magneto P-leads, Ignition switch to starter solenoid, DC outlet jack. | 3 |
| 23-Jun-99 | Added .040 Al backing plates & SS shields for the firewall wiring grommets. The backing plate stops the thin SS firewall cutting through the grommet, & also makes it easier to mount nutplates. | 2 |
| 26-Jun-99 | Dennis Persyk & Dale Ensing, both RV-6A builders, visited from Illinois. Jim Rodrian, Defiant builder, also came over to look at engine baffling. Later I tried to find the right route for the standard length throttle cable. Tried a hole at the bottom of the firewall recess box - wrong. Another hole in the sloping part of the box - wrong. Looks like I'll need longer, custom length, cables. | 2 |
| 27-Jun-99 | Finally tried going below the recess box, above the battery box. Looks like this route is direct enough to give sufficient slack on the firewall side. It needs one of those swivel eyeball clamps from Aircraft Spruce. Tried running fuel from the electric pump to the carb, using a short piece of Al tubing. The throttle lever was still stiff & jerky. Partially disassembled the carb, determined that the stiffness was not caused by the accelerator pump, lubricated the throttle shaft seals with 'fuel lube' ( just moving the throttle shaft in & out about 1/8"). The action is now smooth & considerably less stiff. | 4 |
| 01-Jul-99 | Mounted the 35A alternator from Van's. Needed to joggle the support arm 1/8" (just as Sam Buchanan did). Belt length should be around 33.5". Van's recommends trying a Gates 7350 belt, which fits with the alternator as close to the ring gear as possible, with no adjustment remaining. | 1 |
| 03-Jul-99 | Assembled the heat control box & mounted it to the firewall with an .040 backing plate inside & red RTV to seal it. Mounted the heater air outlet on the back right baffle. Added .040 stiffening plate to the rear left baffle for the oil cooler mounting. | 8 |
| 04-Jul-99 | Further work on the baffle assembly supporting the oil cooler. Fabricated .040 angle pieces to stiffen the assemble. Added .063 angle brace from engine to baffle per George Orndorff. | 5 |
| 05-Jul-99 | Started finishing & riveting baffle assemblies, adding nutplates for the oil cooler mount. | 6 |
| 06-Jul-99 | Riveted & adjusted fit of the left front baffle assembly. | 3 |
| 08-Jul-99 | Riveted & adjusted fit of the right rear side baffle assembly. | 1.5 |
| 10-Jul-99 | Riveted & adjusted fit of the right front baffle assembly. Mounted the new throttle/mixture control bracket. Determined that Van's standard throttle cable is fine, but need a longer mixture cable. | 3 |
| 13-Jul-99 | Mounted the Rapco vacuum pump. Fabricated the bracket structure for the gascolator. Cut the steel tubes to use as spacers for mounting the oil cooler. Primed the gascolator bracket & steel tubes. | 3 |
| 14-Jul-99 | Finished mounting gascolator. Cut hole in cowl for gascolator drain access. Added lower support strap to keep gascolator in place when draining. Fabricated the 3/8" Al fuel line from firewall to gascolator. | 4 |
| 17-Jul-99 | Mounted the eyeball firewall fittings for throttle & mixture cables. Need a 48" mixture cable from Spruce. Mounted the firewall fitting for the carb heat cable & cut the cable to length. Used nutplates to mount the alternator regulator & OV module on the RH fore/aft bulkhead just aft of the firewall. | 7.5 |
| 18-Jul-99 | Mounted the vacuum system regulator & filter units. Connected hose from vacuum pump to bulkhead regulator fitting. Wired up the alternator regulator & OV module to the panel breaker & the alternator. | 4 |
| 24-Jul-99 | Final mounted the carb. Used lock tabs as supplied for the FAB mounting plate. Used serated lock washers for mounting the carb to the engine, with the throttle/mixture cable bracket sandwiched between. Torqued all of these to 40 ins/lbs. Fabricated a clamp for the mixture cable. Made a bracket for mounting the primer solenoid valve. Mounted primer solenoid, wired it & ran 1/4" Al tube to gascolator. | 7 |
| 25-Jul-99 | Added the 1/8" Cu tubing for the primer fittings, using 1205 deg F silver solder to join the brass union fittings to the Cu tubing. | 3.5 |
| 01-Aug-99 | Fitted the two fuel & two oil hoses (AE-466) fabricated & tested by Aeroquip at Oshkosh. Mounted the oil/air separator on the firewall. Mounted the engine sensor manifold on the firewall. | 6 |
| 02-Aug-99 | Fabricated two pieces to fit on top of the baffling to enclose a plenum cooling chamber. Used cardboard for templates, then bent the final pieces from .032 aluminum. | 8 |
| 03-Aug-99 | More work on the plenum. | 6 |
| 04-Aug-99 | Fabricated the plenum air inlets to match the cowling. | 2 |
| 07-Aug-99 | Added .063 angle stiffener for throttle/mixture area of sub-panel. Worked on the sub-panel labelling. Gerry Thorpe visited. | 6 |
| 08-Aug-99 | Completed labelling, using Avery labels 8667. Best process proved to be a coat of Valspar semi-gloss lacquer over the Valspar grey enamel, then the labels, finished with another coat of lacquer. Removed rudder pedal assembly so that it may be reinforced per Van's Service Bulletin. | 6 |
| 09-Aug-99 | Ordered the rudder reinforcement pieces from Van's. Used soft rivets to mount tie-wrap bases along the top of the sub-panel. Mounted the sub-panel pieces & replaced the switches. | 2 |
| 10-Aug-99 | Tie-wrapped the wiring bundles to the top of the switch sub-panel. Remounted the primer tubing using steel T fittings. | 1 |
| 12-Aug-99 | Final fitting of throttle & mixture cables through firewall eyeball units. Made a brass bushing to reduce the 1/4" mixture arm hole to 3/16" to match the rod end bearing. | 2 |
| 15-Aug-99 | Used .040 Al plate to mount a connector block for trim wiring & governor mounting above the MAC switch & display. Wired the Matronics servo governor to the MAC switch & display unit. Connected the servo wiring from the tail. All tested out OK. Still need to connect the coolie hat on the pilot's stick. | 6 |
| 21-Aug-99 | Drilled the teak stick grips to the sticks & tapped 6-32 for countersunk screws, to be used along with RTV to mount the grips. Added the PTT & trim switches using RTV to glue in place. Wired the pilot side switches. | 7 |
| 22-Aug-99 | Fixed .063 angle along engine center line between fore & aft baffles. Drilled plenum top covers to the angle & trimmed to fit. | 5 |
| 25-Aug-99 | Further work on the plenum. | 1.5 |
| 26-Aug-99 | Further work on the plenum. Worked out fittings for oil & fuel pressure. Measured required -4 hoses at 13" & 22.5". | 2 |
| 27-Aug-99 | Added some angle pieces at the front of the baffle/plenum. | 1 |
| 28-Aug-99 | Mounted nutplates on the plenum/baffle. | 6 |
| 29-Aug-99 | Removed the baffling/plenum. Drilled mounting holes 1/64" oversize. Prepared for priming. | 6 |
| 30-Aug-99 | Patched a couple of the larger holes in the plenum cover. | 1 |
| 31-Aug-99 | EAA Technical Counselors, Bill Groeneveld & Tom Willis, & EAA 1158 president, Howard Kaney, visited to inspect the project. | 3 |
| 05-Sep-99 | Made up the 4awg cable runs from the alternator to the 80A fuse to the live side of the starter contactor. Also the 2awg cable from the switched side of the starter contactor to the starter motor. | 4 |
| 16-Sep-99 | Started wiring up the EIS-4000 engine monitor. | 1 |
| 17-Sep-99 | Tapped the flared side of the steel fittings at the engine for the fuel & oil pressure sensors. Drilled AN3 bolts with #59 bit. Used loctite to secure the bolts in the fittings, then cut off the heads to leave restrictor fittings. | 1 |
| 18-Sep-99 | Redid the wiring for the audio panel - it was cut to re-route the wiring to the headphone jacks. | 2 |
| 18-Sep-99 | Took the wingtips to Jim Rodrian, who showed me how to glass the nav/strobe light mounts in place. We used 40 grit sandpaper to remove the wing tip gel coat, then two layers of bidirectional 8.8 oz cloth & aeropoxy resin. | 2 |
| 19-Sep-99 | Fabricated & fitted the 2awg ground cable from the firewall ground block to the engine. | 1 |
| 20-Sep-99 | Sanded the wingtip mounts & used a dremel tool to cut out the holes for the light mount. Wired the nav light switch to the dimmer input on the MAC trim display. | 2 |
| 21-Sep-99 | Fitted the 2awg cable from master to starter solenoid, through a firewall shield. | 2 |
| 25-Sep-99 | Wired & tested the co-pilot stick PTT switch. Mounted the EGT probes 2 3/4" down the exhaust pipes. Fitted the firewall shield for the CHT/EGT probe wires. Added adel clamps to the engine mount to support various wires. | 5 |
| 26-Sep-99 | Prepped & primed all the engine baffle pieces with SW wash primer. | 4 |
| 27-Sep-99 | Riveted baffle pieces together & mounted on the engine for the final time, I hope. Mounted the oil cooler & connected hoses. | 4 |
| 29-Sep-99 | Sanded the old paint off the rudder assemblies which had the reinforcing pieces welded by Erik Andersen, President of EAA Chapter 18. | 2.5 |
| 30-Sep-99 | Primed the rudder pedal assembly | 1 |
| 01-Oct-99 | Painted the rudder pedal assembly. Installed the SCAT ducts from baffle to heat muff to firewall heat selector box. Installed the cooling blast tubes in the baffle holes. | 2 |
| 04-Oct-99 | Installed & safety wired the oil temperature sensor. Wired the fuel & oil pressure sensors, using a 200ohm resistor & the 4.8v excitation connection for the fuel pressure to give a 0-10psi range. Used Aux 1 for fuel pressure, with scale factor & offset at 250/47. | 2 |
| 19-Oct-99 | Wired the EGT & CHT probes with the supplied spade connectors & shrink wrap tubing. | 1.5 |
| 20-Oct-99 | Reassembled the rudder pedal/brake units & reinstalled the complete assembly. Used #8 screws & lock nuts (& a couple of pop rivets) to mount the adel clamps supporting the 1/4" Al brake lines & fuel vent lines. | 4 |
| 21-Oct-99 | Called Van's & then Sensenich (717-569-0435) to sort out my prop order. Sensenich now recommend 72FM8S9-1(83) rather than -0(81). My order (Sensenich #99-0980) has been changed accordingly & is scheduled to ship end of November. | |
| 21-Oct-99 | Completed final assembly of throttle & mixture cable ends to carb using drilled bolts & cotter pins. Added supporting adel clamps for the EGT/CHT cables on the firewall. | 2.5 |
| 22-Oct-99 | Made mounting bracket for fuel flow sensor. Ran wiring for fuel sensor. Fitted fire sleeve to Al fuel lines from bulkhead to gascolator & gascolator to primer solenoid. | 2.5 |
| 23-Oct-99 | Used #6 screws into two nutplates to mount the manifold pressure sensor module, beside the alternator regulator, & wired it to the EIS-4000 Aux2 input. Scale factor & offset were set to 140/86 which gave a reading of 290? Secured the ends of the cooling blast tubes directing air to the alternator, fuel pump, gascolator & magnetos. | 2 |
| 26-Oct-99 | Added a cooling blast tube for the vacuum pump. Tied the lower curved baffle pieces together with .041 safety wire twisted inside brake tubing & secured at each end with a piece of hinge pin, with a blob of JB Weld to keep the pins from slipping. Torqued the exhaust mounting nuts on the blow-proof washers, 120 in/lbs (Vetterman specified 100-140 in/lbs). | 2.5 |
| 27-Oct-99 | Remade the 3/8" Al fuel line from the selector to the electric boost pump - the original had a couple of bends that had flattened to less than the allowable 75% diameter. | 1.5 |
| 28-Oct-99 | Fabricated the short 3/8" Al fuel line from the gascolator to the fuel flow sensor. Completed & primed the mounting structure for the fuel flow sensor. Installed the 3/16" OD Nylaflow tubing between the manifold pressure module & the firewall sensor manifold. | 2 |
| 29-Oct-99 | Mounted the fuel flow sensor with fire sleeve on the Al line from the gascolator. | 1 |
| 30-Oct-99 | Drilled 3/16" holes between the rivet holes in the lower cowl hinges. Used West System epoxy resin & 3/4oz glass cloth 3/4" strips (from the hobby shop) to secure the hinges, cleko'd in place till the resin began to harden. | 2.5 |
| 31-Oct-99 | Riveted the hinges to the lower cowl. Epoxied the hinges to the upper cowl. Made .032 plates to carry 3 K1000-08 nutplates each side of the front of the lower cowl. Used 3 layers of 9oz bid cloth to make an indentation in the FAB for clearance from the nose gear leg. | 6.5 |
| 01-Nov-99 | Riveted the nutplates to the lower cowl. Began preparing the upper cowl hinges for riveting - drilled the epoxy out of the rivet holes. | 1 |
| 02-Nov-99 | Riveted hinges on upper cowl, until I ran out of AN426AD3-4s. | 1 |
| 03-Nov-99 | Finished riveting hinges on upper cowl. | 1 |
| 04-Nov-99 | Finished mounting the fuel flow sensor adding the new teflon hose from the sensor to the mechanical fuel pump. | 2 |
| 06-Nov-99 | Created the tunnel in the air scoop to the FAB mouth. Used two layers of 9oz bid cloth from outside the air scoop, inside the tunnel Redid the FAB indentation with two layers of bid cloth on the outside.. | 4 |
| 07-Nov-99 | Chipped out the foam from around the air scoop tunnel & trimmed the tunnel to leave 1/4" gap to the FAB mouth. Added a third layer of cloth to the other side of the air scoop. Added a third layer inside the FAB. | 3 |
| 10-Nov-99 | Pop riveted baffle material around the FAB inlet. Installed the 69106 governor drive pad cover in place of the governor drive unit. Torqued the nuts on the 5/16" studs to 200 in/lbs per Lycoming manual. The cover was $21.30 from Preferred Airparts, Ohio. | 2 |
| 11-Nov-99 | Epoxied the air scoop to the lower cowl, using a layer of 3/4oz cloth between the pieces. Added epoxy cotton flock paste to fill gaps, then used soft 3/32 CS rivets (from wing tip kit) at 3" intervals to hold it in place. | 2 |
| 12-Nov-99 | Added two layers of 9oz bid cloth on the inside of the air scoop to cowl joint. | 2 |
| 14-Nov-99 | Flew with Mike Seager in Portland | |
| 20-Nov-99 | Sanded the air scoop to cowl joint. Painted a thin layer of resin inside & filled the outside gap with resin & micro balloon mixture. Squeezed the final rivets in the upper cowl hinge. | 3 |
| 21-Nov-99 | Sanded the air scoop joint. Mounted one of the lighting units on a wing tip. Used a knife connector for the forward light connection. Added an extension cable for the strobe connection. Tested both strobe power supplies. | 2 |
| 22-Nov-99 | Mounted the second lighting unit, completed & tested the wiring. | 1 |
| 24-Nov-99 | Fabricated a restrictor fitting for the manifold pressure sensor the same as the oil & fuel pressure fittings. Fitted the hose for manifold pressure. Added the 8 pin molex connector for the altitude hold module. | 2 |
| 25-Nov-99 | Painted the seat backs with a coat of gray primer followed by one coat of gray enamel. Painted the forward side of the removable baggage compartment back wall with one coat of gray primer & two coats of gray enamel. Used an epoxy cotton flox mixture to build up the lower aft corners of the lower cowl to match the fuselage radius. | 2 |
| 26-Nov-99 | Rechecked the 175 in/lbs torque on the engine mount to firewall nuts & fitted the cotter pins. Sanded the lower cowl corner build-ups. Did miscellaneous tidying up of tie-raps etc. firewall forward. | 2 |
| 28-Nov-99 | Torqued the primer tube fittings to 30 in/lbs. Did final fitting of exhaust pipe supports. Riveted the plenum front pieces with Tom. Built the support structure for the aft edge of the air scoop. Had to fabricate new U-620 & U-621 because the distance from the air scoop edge to the underside of the fuselage is 4" instead of the 3 1/4" in the plans. Must just be the shape of the air scoop? | 6 |
| 30-Nov-99 | The upholstery, ordered at Oshkosh, arrived from Cleaveland Tool. | |
| 04-Dec-99 | Visited the RV's under construction at EAA Oshkosh. Final mounted the FAB. Connected the carb heat SCAT tube from the heat muff, & connected the carb heat contro cable. Decided routing of breather output from oil separator. Rivetted single hinge eyes to bottom edge of firewall. Made new lower cowl attach hinge pins the right length to clip into the single eyes on installation. | 4 |
| 05-Dec-99 | Ran 2x RG-58/U coax through the left rail conduit - 1 com & 1 nav. Also 1x RG-58/U through right rail conduit - 1 com. Both conduits are now pretty full! | 3 |
| 06-Dec-99 | Ordered ELT, altimeter, airspeed, VSI, fuel level, battery etc. from Van's. Ordered OAT & carb temp probes from GRT. Ordered Navaid wing leveller plus Smart Coupler from Navaid Devices - delivery 12 wks. Ordered Sigma-Tek gyros, Astrotech clock, battery charger, fire extinguisher, mag timer etc. from Aircraft Spuce. | |
| 12-Dec-99 | Fabricated a formica panel template & drilled the centres for the flight instruments. | 2 |
| 18-Dec-99 | Cut the left section of the instrument panel. Used a fly cutter on the .063 sheet to cut the instrument holes. Made templates to drill the mounting screw holes. | 8 |
| 19-Dec-99 | Cut the centre & right sections of the instrument panel. Cut away most of the original panel, leaving framework to attach the three piece facia. Added .063 angle either side of the 6.25" radio stack opening. Mounted the EIS-4000 engine monitor with its face plate behind the panel. | 10 |
| 23-Dec-99 | More instrument panel work. Cut the 1" hole for the vacuum gauge. Wired the fuel level gauge & the clock backlight. Added nutplates mounting the panel facia. | 6 |
| 24-Dec-99 | Fabricated a door to restrict airflow through the oil cooler. Set up the cable routing. Also set up the cable controlling the cabin heat. Cut holes in the bulkhead for the hoses to the vacuum gauges. | 7 |
| 25-Dec-99 | Installed the battery. Fabricated the +ve cable, but need another lug for the ground cable. Moved the main bus fuse block slightly to avoid interference with connectors on adjacent avionincs fus block. | 3 |
| 27-Dec-99 | Cut slots in the battery box to clear the battery cables. Mounted the fire extinguisher on the aft face of the battery box. Mounted the ELT on the fore-aft rib behind the elevator bell-crank. Used two .040 angles to reinforce the mounting area. | 7 |
| 28-Dec-99 | The Sensenich propeller & spinner arrived. Checked the fit of the cowling with the propeller spacer & spinner back plate. Installed batteries in the ELT main & panel units. Tested the ELT, using the Icom A4 to monitor 121.5 (tested in the first 5 mins of the hour). Added .040 channel behind the vacuum gyros to stiffen the panel in this area. | 3 |
| 29-Dec-99 | Ran the ELT control panel cable through the left fuselage conduit, replacing the com antenna cable. Started fitting the ELT & Nav antenna cables through bushings to the tail cone. | 2 |
| 31-Dec-99 | Moved the elevator trim cable from right to left fuselage conduit, so that all wires to the tail go down the left side. Pop riveted tie-wrap mounts to the J section to support the wiring. Completed the ELT anenna cabling | 6 |