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3 Jan 06        4 Hours        Cum: 595

Trimmed and fitted the wing root fairings for the right wing.

4 Jan 06        2 Hours        Cum: 597

Began cutting away the top skin on the right flap to fit it to the wing and the fuselage.  Slow, tedious work on the first wing, but the second one should go much faster.

10 Jan 06       14 Hours        Cum: 611

Cumulative time over several days.

Working on fairings for right wing - especially the flap fairing.  It's confusing to read the plans and builder's manual, but once you fit it to the plane it makes more sense.  Also trimming flap, setting aileron stop, making additional fairing to add to the flap fairing, and work on the left console upper cover.

The 60 Amp Internally Regulated Alternator I ordered from Plane Power arrived.  It looks like a great product.  We'll see how good it really is when it starts spinning.  You can see them at www.plane-power.com,

14 Jan 06        6 Hours        Cum: 617

Today we worked on making a fairing to fit on the flap fairing to cover the hole left when the flaps are down.  We just don't like the way it looks and it might catch mud or other "stuff" so we'd like to close it off with a fairing.  To do that, you have to design and make your own.  Nelson worked on fitting the new left console top cover and it looks great.

16 Jan 06        7 Hours        Cum: 624

Work time is for 15 and 16 Jan.  The right wing is essentially finished with the mounting process.  We riveted the flap fairing in place and the fairing came out nice.  We've fitted the flap to the fairing and found there was a lot of trimming.

17 Jan 06   

Big day today!  I ordered an IO-390 from Barrett Precision Engines in Tulsa, OK.  They are builders for numerous aerobatic competitors and airshow pilots and they have a great reputation.  Their price is more than others by a couple of thousand, but they are more than willing to work with me to get the engine how I want it.  Plus they do some porting work to improve the airflow through the engine.  They are also going to mill the heads for me about 15 thousandths to increase compression.  Allen Barrett (planning to start a RV-8 soon) told me that they are getting about 217 HP from a stock IO-390 on the dyno.  They do a dyno run on all the engines they build and include the results with your shipment.  I see that as extra insurance.

The engine will have Airflow Performance fuel injection, Skytec starter, chrome package, and P Mag electronic ignition.  I'll also use the ADC oil filtration system and Plane Power 60A alternator.

With the higher compression, I think it will produce 220+ HP without straining. 

22 Jan 06        4 Hours        Cum: 628

Got to work on the left wing fairings and they are coming along fine.  Taking time to do it right produces a nice looking fairing.  I do wish Van's had devised a fiberglass fairing as I think it would look better and would probably improve the aerodynamics.  Tomorrow we fit the aileron and flap and begin trimming the flap skin.

Some time ago I heard about a fellow who was planning to make carbon fiber fairings for RV fuel vents, fuel drains, and aileron brackets.  He recently finished the design work and I bought a set from him.

23 Jan 06        4 Hours        Cum: 632

24 Jan 06        4 Hours        Cum: 638

Fitting the left flap.  It requires lots of trimming and multiple fittings.  Oiling the hinge pin is important because it is inserted and removed many times.  Nelson also got the FCP NACA scoop installed, remade the flap weldment nutplates, and sealed a few spots with proseal.  He also pointed out that the step should have been installed before the flap fairing.  Well, too late now, so we'll either have to drill out the fairing rivets and reinstall it with the step or I'll have to figure out a way to do without a step.  One guy locally built his 8A without the step (intentionally) to save weight and drag.   He uses a footstool for passengers to climb aboard and just stretches himself to climb on the wing.

29 Jan 06        4 Hours        Cum: 642

More fitting of the left flap.  Got the bends made in the inboard edge of the lower skin.  Also, we have an issue with the flap torque arm operating stiffly.  When we tighten down the Delrin blocks that the flap arm rotates in, it becomes too tight to operate.  So, we're going to add shims below the floor panels to bring the blocks to level.  That seems to help, but doesn't eliminate the too tight fit of the flap arm.

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30 Jan 06        4 Hours        Cum: 646

Last details on left wing before removal.  Also, the WD-806 Flap Arm is working smoother.  With the way the Delrin blocks that hold the flap arm pull down, they were binding on the ends of the flap arm making it too tight to move freely.  Probably a good reason why so many flap motors are quitting.  We added shims under the floor panel to bring the blocks up to level.  Also, the flap arm tends to wander left and right about 3/4 inch, so we cut two equal sized spacers from 1 inch ID PVC and placed them between the flap arm and the Delrin block.  They move smoothly against the blocks and keep the flap arm centered.

31 Jan 06        3 Hours        Cum: 649

Removed the left wing, rebuilt the wing rack, and put the wings into the storage racks.

1 Feb 06        3 Hours        Cum: 652

Nelson recommended adding connectors to the floor panels to add in strength after they were cut to make the floors removable.  So much of today was spent making and attaching connectors for the panels below the rear seat.  We also organized some of the interior parts that need to be painted.

2 Feb 06        3 Hours        Cum: 655

Nelson suggested we buy a charcoal grill to cook burgers at the shop.  What a great idea!  We had the first burgers today and they tasted very good.  In addition to filling our bellies, we also prepped some of the interior parts for painting and tried fitting the gear legs into the gear mounts.  Good thing we tried them because they didn't fit.  Also they tend to rust if allowed to sit for a long period.  SO, if yours will be stored for a long time before installation, then you would be wise to oil the unpainted parts and cover them with oiled cloth.  You'll thank yourself later.

To open up the gear legs, we bought a 2" hone and carefully honed out the interior of the gear leg weldments.  They opened up perfectly and the gear legs fit tightly into the weldments.  Tomorrow we're going to ream all of the mounting holes to insure they are ready for final mounting.

3 Feb 06        2 Hours        Cum: 657

We carefully opened up the 5/16 holes in the top of the gear legs and mounts.  We did it in assembly.

I suggest you step up with drill bits as you open the hole.  Use 9/32 (if required), then 19/64, and finally ream it out with a 5/16 reamer.  We tried using primarily the reamer and that does not work as well.  We finally got them cut satisfactorily, but it could've been an easier, faster, and better job if we had stepped up the sizes.

8 Feb 06        4 Hours        Cum: 661

We decided to take the big leap and paint as much of the cockpit and interior parts that we could get done.  We surprisingly got much of the painting done and it turned out reasonably good.

13 Feb 06        3 Hours        Cum: 664

It's time to put parts in the plane for the final time.  Today we worked on the bulkhead doubler that has to b installed for the step.  For some reason, a .032 doubler is to be added to the bulkhead just forward of the step.  Getting the doubler to fit is challenging.  We also began the main landing gear mount installation.  We'd forgotten the .040 shims so those had to be made.  The gear weldments fit reasonably good.  Some time ago I had to ship the right weldment back to Van's to fit in the jig for straightening.  The slight adjustment they made (1/16") was all that was needed.

19 Feb 06        6 Hours        Cum: 670

Installed the canopy bow/roll bar and the front seat support weldments.  Not difficult to install, but time consuming.  It's easy to overlook, so make sure the bolts on the outboard edge of the roll bar are inserted with the bolt from the bottom.  Otherwise, the bolts will be in the way of rivets that must be installed.

20 Feb 06        4 Hours        Cum: 674

Today we installed the F-821BPP strips for the baggage door.  Now it's time to fit the top skin.

21 Feb 06        5 Hours        Cum: 679

Happy Birthday to me.  29 yrs old.  : )

We got the F-821PP top skin fitted and drilled and clecoed today.  Also made shims for the edges of the instrument panel and got started on the baggage door.

22 Feb 06        5 Hours        Cum: 684

More work on the top skin and planning for the Skybolt fasteners for the cowling.

1 Mar 06        16 Hours        Cum: 700

Hours spread over three days.  Strapped the baggage door to the fuselage top skin and pulled it tight to get a nice fit.  The plans are confusing in several respects regarding construction of the baggage door, but it turned out to be fairly straightforward once we studied the plans and manual for several hours.  Had to climb inside the fuselage to drill the door frame in place.  However, that was the worst of the job.  Once drilled, it laid out nicely and the inner skin fit well.  Pulled everything off and deburred and dimpled the F821 skin and the baggage door.  Then primed and began riveting the frame on the door.  Made the locking rods, opened up the tooling holes in the door frame, and inserted the bushings.  They don't mention that you have to open up the 1/4" bushings to allow for the 5/16 rod.  But with a little rattail file work, it turned out nice.  Instead of the recommended stop nut on the screws which attach the rods to the lock in the center, we attached half of a #6 nutplate using pop rivets through the wall of the rod.  Makes a more user friendly mechanism and eliminates the need to taper the rods.  Will paint more interior parts on Sunday.

5 Mar 06        8 Hours        Cum: 708

Nelson got a lot of work done on various things while I was gone.  Today we painted most of the remaining interior parts.  However, we're not happy with the finish on some of the parts so we're going to repaint some of them.

6 Mar 06        5 Hours        Cum: 713

Mostly planning of wiring runs and autopilot connections.

7 Mar 06        5 Hours        Cum: 718

Installed magnetometers and mag cables.  Very time consuming.  Ran position light wires to tail along with ELT coax.  Forgot the run the trim motor wires so will have to do that later.

The mag wires need to avoid interference from other wiring as much as possible so routing them took careful consideration.  The cables themselves compound the problem because they are standard computer 9 pin cables so the connectors are large and would require 1.5" holes.  We got around that by drilling grommet-sized holes near the control column holes, cut a slot to insert the wires, and adding a doubler to maintain strength in the underfloor bulkheads.

13 Mar 06

15 Mar 06        4 Hours        Cum: 722

16 Mar 06        6 Hours        Cum: 728

Finished up the mounts for the switch panel LEDs.  They should work fine and I ordered more of the LED strips to use for console lighting, panel lighting, and baggage lighting.  We need to add so much bulk to the conduit in the left side of the aircraft that we decided to remove the small conduit and replace it with 7/8" conduit.  We're about ready to install the pitot-static lines also.

20 Mar 06        7 Hours        Cum: 735

Installed main grounding block on aft side of firewall.  Installed main battery mount and F-889 panels.  Installed the rudder pedals and discovered the pedals rub on the F-847s when the pedals are moved.  The right side will be fine after changing a cotter pin, but the left one requires work.  It needs a stiffener to take out a light bow and a channel at the top to connect it to the baggage floor.

Got the AP aileron servo installed and attached.  I'm trying to find out from other builder how much stick throw they have from side-to-side so I can compare it to mine to make sure I'm not restricting stick movement with the over-center stops I added for the servo.  BMA recommends as close to 60 degrees of servo arm travel as possible but to ensure there is no chance of going over center.

The load plan is getting closer and the electric system is becoming finalized.  We're going to start stringing wires.

21 Mar 06        6 Hours        Cum: 741

Added the stiffener to the left F-847 and the U channel at the top.  It's going to be challenging to remove that panel in the future if needed, however it should rarely need to be removed since the fuel pump and filter will not be located behind it.  The pumps (one for each tank) will be at the wing root between the wing and the fuselage.  Much better for safety!  The fuel lines will come into the cockpit to the selector and then to the engine.  I'll mount the fuel filter on the firewall.

Reinserted the rudder cables with the tube guide at the tail and the tubing under the front seat.  I ordered a Trim Mixer from Ariel ATE of Israel.  It's a trim mixer that permits either stick to make inputs, but the pilot can selectively turn off the aft stick.  I've posted info on the Recommended Products page.  Got more circuit breakers from Aircraft Spruce and the Whelen installation kit.  Also, more of the LED bars from theledlight.com.  The LEDs seem as though they will be right for the interior lighting.

Went to the local battery shop (Posey Power) and had them make two #2 AWG cables for the main battery ground and starter contactor connection.  They did a nice job in 5 minutes and it was well worth the $6.50 cost.

22 Mar 06        5 Hours        Cum: 746

23 Mar 06        6 Hours        Cum: 752

Added a few of the battery cables.  The main battery is starting to be populated with wires.  It's time for me to start labeling wires using the computer or to buy a label maker.

We realized that the left rudder cable is going to rub on the step mount so we called Van's and they are aware of the problem and suggested adding UMHW tape on the contact area and just check it periodically.  I'm not too keen on that idea so we're having our favorite local welder cut a groove for the cable and weld back in a trough for it to pass through.  We'll add the tape for additional insurance.  Also, I don't like the angle that the step is in relation to the fuselage.  It tilts away from the fuselage several degrees and looks odd.  So the welder is going to correct that problem, too.

More work making the mounts for the LED console lights.  It's time-consuming, but should prove to be worthwhile.

27 Mar 06        9 Hours        Cum: 761

Numerous things going on today.  Straightened out the small dent in the fuselage and it came out very nice.  Very slight filling and sanding to do.  Finished making the LED Flood light mounts for the consoles.  They will work fine and the light produced is just right.  After some consideration, I've decided to wire the RCP Floods and the aft baggage lights together on the same dimmer and inline fuse.  All other floods will be on separate dimmers and the front baggage will have its own toggle switch so I can open the front baggage and flip on the light without opening the canopy.  Tomorrow we're going to put together the wheels and tires so we can put the fuselage on the gear in a week or so.  Sun n Fun begins a week from tomorrow, so we're making a list and checking it twice.

28 Mar 06        6 Hours        Cum: 767

Today we built up the wheels and tires.  It was a bit time-consuming, but with persistence, we overcame the tire's resistance.  Picked up the updated step from the welding shop and it looks like it will work better.  The welder did a superb job of welding.

Also, Nelson had a great idea for installing the two power receptacles I wanted that will keep them out of sight yet make them easy to access.  I intend to use them for gooseneck map lights at night and for any use in the day - such as handheld GPS, small 12v heater or blanket, cell phone charger, etc.

3 Apr 06        8 Hours        Cum: 775

4 Apr 06       

First day of Sun n Fun.  I have lots of things to buy.

5 Apr 06        7 Hours        Cum: 782

First day of SnF was low key.  Only the hardcore are there on Tues, Wed, and Thursday.  Not too crowded.  Bought six aluminum air vents so I have choices.  I'll sell what I don't use.  Also bought $167 worth of hardware.

A couple of old USAF buddies came by the shop today and helped with a couple of things.  Ron "Gunner" Moore and Steve "Cords" Courtroy are here for SnF and they came by the shop and drank beer.  Today, they even brought beer!  Gunner has flown F-4s, F-16s, A-10s and C-130s.  We flew together in Germany.  Cords and I fought at Red Flag at Nellis AFB.  Cords has flown F-5s, F-16s, A-10s and B-737s.

We ran more wires today for several things.  Nelson worked on the fuel pump enclosure while I worked on mounting the Trim Mixer.  We're installing a vapor-proof box around the fuel pump to vent vapors outside to help avoid fuel vapors escaping inside the fuselage.  Steve helped me wet-sand the canopy side rails and we polished them some.  I'll install the rails as soon as possible along with the console lights.

8 Apr 06        8 Hours        Cum: 790

Nelson is making brackets for the fuel pump box.  I installed the OAT, the electrical receptacle plugs and polished the canopy rails.  The receptacles ops checked good.  I'm installing the OAT under the left wing in the hole meant for the aluminum tube pitot tube.  I'm using a heated pitot and thus don't need the hole that is predrilled on the quickbuild kits.  Finding a way to mount the BMA OAT was challenging.  Finally made a little .032 bracket for an adel clamp to hold the OAT probe in place.  Also inserted a rubber grommet in the hole to keep the probe from touching the edges.  Overall, the OAT mount is solid and seems to be in a good location.

Nelson has to leave about 15 Apr so we're going to do a few final projects before he leaves.  We'll get the wing skins riveted on since those are a two-man project.  Then I can work over the summer on one-man projects.

Bought more hardware at SnF this morning.

10 Apr 06        9 Hours        Cum: 799

Went to SnF early for some last minute shopping.  It's never too early to start Christmas shopping - for myself, that is.

Ordered several things from ACS since they are offering free shipping during SnF.  Ordered the Infinity Stick grips.  Added a chip detector option to the ADC oil filter.  Made a huge decision to use a 3 blade Hartzell instead of a composite prop as originally planned.  I'd always thought I would use the Aero Composites 3 blade, but this year the price is almost $15,000!!  For me, they've priced themselves out of the market.  I've heard about some ADs on MT props lately so that may rule them out.  The 3 blade Hartzell is only 10 pounds heavier than a two blade and only 6 pounds heavier than an Aero Composites prop.  And the Hartzell price new with a polished spinner is under $7,000 and an overhauled one is $5,000.  So, that makes more sense and I'll just have to learn to live with the heavy nose.

Nelson got the fuel pump vapor-proof box almost finished.  Then we got started on riveting the final wings skins on.  It goes fairly good with us working together.  I finished polishing the canopy rails and installed the right one with the LED floods underneath.  The lights ops checked okay.

11 Apr 06        10 Hours        Cum: 809

Huge progress today.  Got the wings completely closed now.  The bottom skins are installed.  Also more fine tuning of the fuel pump vapor box and installation of the left canopy rail and FCP console flood lights.  This electrical wiring stuff is getting easier ... and more fun.

12 Apr 06        8 Hours        Cum: 818

Did a test run on the fuel pump.  Nelson built a vapor enclosure for the fuel pump so that in case there is a leak the fuel vapors will be vented outside.  The interim plan was to mount the fuel pumps at the wing root external to the fuselage, but the Van's Airflow Performance pump doesn't fit well in that position.  So, we brought it back inside and built the vapor enclosure.  Installed a vent for the enclosure just aft of the normal fuel vent and installed the fitting through the firewall for the fuel system.  The Andair selector should arrive next week and we can get it all together.

Installed the modified step and it came out fine.  We noticed at SnF that the step mountings were ugly.  So, we decided to mount the step using flush rivets for those that are exposed, to get a better fit of the flap fairing over the step, and to do some filling and sanding to make the step look better.  The results will show after the paint is on.

13 Apr 06        8 Hours        Cum: 826

Woo hoo - lots done today.  Routed the rudder lights and strobe wiring and installed a terminal strip to bring all wires to and then they will continue to the trim and position light.  Also installed the elevator bellcrank and push-pull tubes.  We cleaned up all wiring bundles to the tail and overall it's looking neat.  We're fitting the aft stick now and the front one will be later.  Part of the floor and the flap torque arm can go in tomorrow.

14 Apr 06        10 Hours        Cum: 836

Decided to fit the engine mount to the fuselage.  It sounds easier than it was.

We drilled out the firewall holes and began fitting the mount.  It didn't fit.  The holes were off slightly which means the mount probably was at fault.  So we proceeded to make the mount fit.  It was close, but needed a little persuasion.  So, we used racheting straps and pulled the mount the extra 0.1 inch needed to fit.  Then we had to drill the lower mounting holes and install the bolts, castle nuts and cotter pins.  The 1.4 inch diameter hole to work in for the lower bolts makes the install challenging.

Later I installed the AOA Sensor lines

15 Apr 06        8 Hours        Cum: 844

Today's primary task was to install the main gear legs, wheels and tires.  Thanks to preparation months ago on the gear legs, the job was not too bad.  The gear legs were prepared months ago by insuring they would fit in the main gear mounts by reaming for the single attachment bolt in each gear leg.  Also, Nelson smoothed and brightened the gear leg mounts and had protected them with corrosion preventative.  Van's has done some precision machining when building the gear legs and they fit very tight.

We put the wheels on the gear legs before putting the gear legs on the fuselage.  That way we could more easily mark the holes for the wheel retention nut cotter pins.  Drilling those was fairly straight forward.  The first wheel was difficult to get on the axle, but once we developed some techniques, the second one was easier.

We removed the wheels and, with the fuselage suspended from the rafters, we inserted the gear legs.  Once those were in place with the bolts holding them, we slid the wheels on.  The retaining nuts turned right to the drilled cotter pin holes and the job was done.  We also trial fitted the nose gear strut and it was no problem.  The nose gear is off for now until I'm ready to hang the engine.

The plane looks cool sitting on two gear.  It looks like what the RV-8 should look like - the RV-4 with it's aft slanted gear.  Nelson will be heading north for the summer before too long and he has me on track to get a lot of things done this summer.  Having his help this winter has been incredible.  It would have taken me four times longer to do the same work solo - and some of it would have been virtually impossible solo.  So, I can't thank him enough for motivating me and helping me get vital steps done.  We've had fun doing the work and grilling burgers and steaks at the shop and drinking beer.  I'm looking forward to his return in the fall.

With the plane on its gear we had to build something to be able to work in the fuselage.

18 Apr 06        5 Hours        Cum: 849

Made the mounts for the Aft Baggage LEDs.

19 Apr 06        5 Hours        Cum: 854

Wired the Baggage LEDs.  The ACS 600 Brake reservoirs arrived.  I plan to mount them on the master cylinders.

20 Apr 06        6 Hours        Cum: 860

Got the RCP console LEDs finished, wired, and installed.  The Periheliondesign.com dimmers work fine.  I've ordered knobs for all dimmers.  The RCP dimmer controls the RCP console LEDs and the aft baggage LEDs.  I don't mind if the baggage LEDs are on in flight at night.

25 Apr 06        5 Hours        Cum: 865

Stringing wires for the trim mixer and trim servos.  I'll finish mounting the aileron trim mixer tomorrow.

26 Apr 06        4 Hours        Cum: 869

The aileron trim servo is installed.

1 May 06        1 Hour        Cum: 870

2 May 06        5 Hours        Cum 875

Clean up work today.  Filed and sanded down the flush rivets on the step mount.  Nelson and I thought other RVs with the button head rivets on the step were ugly.  So, we decided to use flush and then sand to make them disappear.  Done.  Also filled some pop rivets on the ailerons and flap fairings with Super Fil and began some sanding.  Lots of sanding awaiting me tomorrow.  Then climbed into the aft fuselage to secure the ELT remote switch wire.  I combined the static line, strobe wires, standby battery ground, and ELT wire into Adel clamps.  They seem to be very secure now.

9 May 06        5 Hours        Cum: 880

Cleaned up some wiring runs.  Installed the flap floor and flap arm.

14 May 06        5 Hours        Cum: 885

19 May 06        2 Hours        Cum: 887

More sanding on flap fairings.  I've learned to go lightly on the filler because it is hard to sand.  I can't understand how the composite builders can stand the hours of sanding required.  Guess that's why I'm building a (mostly) metal airplane.  Got the AOA sensor fitted and drilled to bracket but didn't have the right sized screws, so had to visit the aviation department at Home Depot.

21 May 06        4 Hours        Cum: 891

24 May 06        3 Hours        Cum: 894

Cleaned up the AOA CPU bracket, cut away some metal for lightening, and primed it.  I'll install it tomorrow so I can start running wires from the AOA CPU to the various sensors, inputs, and outputs.  Also, the Flap sensor bracket is ready to install.  Once it's in, I'll be able to do the final wiring for the flap motor.

Now that I'm into it, I regret doing the filler work around the step.  It would have looked fine without any filler and would have saved a lot of time.  But, can't turn back now, so I'm going to have to keep working it until it looks good.

25 May 06        2 Hours        Cum: 896

26 May 06        3 Hours        Cum: 899

Devised a bracket to mount the Andair fuel selector, but I'm not happy with it so I'm starting over.  Bought some driving lights at the local auto parts store but test runs showed them to be less than desirable.  So, I'm back to the Whelen recognition lights.  I'm still unsure about how to do the wingtip lights.  I'm searching for LED headlights.  Those would be perfect if they produce enough light for taxiing.  They would also be flashed for recognition.  They would produce virtually no heat whereas the halogen bulbs produce bucketloads of heat - enough to make me want to ventilate the wingtip with a NACA scoop.

3 Jun 06        3 Hours        Cum: 892

Started over with making the fuel selector bracket.  Got another made and I'm fairly pleased with it.  It's all fitted and drilled - I'll deburr and rivet later.

6 June 06        3 Hours        Cum: 895

Finished the fuel bracket with nutplates for mounting.  I think I'll need to also cut some lightening holes in it - not for lightening but to be able to see the fuel line fittings hidden by the bracket.  I think it will be easier to make the line attachments if I can see "through" the bracket rather than having to use mirrors.

8 Jun 06        3 Hours        Cum: 898

Cut the lightening holes and fitted the bracket and the mid cabin cover.  Traced the holes on the bottom of the mid cabin cover and ... opps, I got the fuel selector a little close a bend in the cover.  It'll work okay, but doesn't look the greatest.  Probably nobody else will ever notice.  So got the holes cut in the cover and ordered some 4-40 screws to mount the fuel selector.

9 Jun 06        1 Hour        Cum: 899

Most work today wasn't on the plane but on making work benches and stuff.  Bought a Brother P-Touch label maker for $29, but when I tried labeling wires and shrinking clear shrink tube over the label, the label turned black because the labels are thermal transfer.  So, to use them I'll have to forego shrink wrapping the labels.  Also got the nose gear parts ready to install.  I'm going to Tulsa on the 15th to watch the engine run and I expect delivery of the engine before the end of June, so it's time to get the nose gear on so it can support the weight of the engine.

15 Jun 06

I met Nelson in OKC and we drove to Tulsa to watch the engine run at Barrett Precision Engines, but they'd had trouble with an IO-550 on the dyno so my engine was going to be delayed.  I didn't have time to wait so I'll just have to see the dyno printout after Barrett's 1.5 hour engine run.

17 Jun 06        6 Hours        Cum: 905

Finished install of the Andair fuel selector.  Now to run the fuel lines.

Also mounted the nose strut and wheel in preparation for the arrival of the engine.

21 Jun 06        4 Hours        Cum: 911

Mostly planning today, but got started on making a bracket to mount the autopilot controller and the ethernet hub.  I've decided to rearrange things a bit after realizing how little room there is behind the instrument panel.  I've decided to keep the high $ avionics fan after recommendations from BMA.  It's a three port fan and I'd considered returning it because of its high price, but the electronics experts claim heat is what kills electronic stuff.  So, the fan is going to take up precious space behind the panel.

In order to free up some behind panel space, I'm going to move the AP controller and the Netgear ethernet hub to a common bracket opposite the strobe power supply and aft of the rear baggage.  There is room in that spot, it shifts a little weight aft, shortens the servo cable runs, places the ethernet hub near the AP controller, and makes access to the ethernet hub fairly easy.

23 Jun 06        8 Hours        Cum: 919

Whew.  Too many different projects within the project going on.  Today worked on a bracket for the Matco parking brake and on a bracket for the AP controller and ethernet hub.

I've considered several different ways and locations to mount the parking brake, including activating it with a Mac trim servo.  Discarded the servo idea after a test showed it was too slow.  I don't like the typical pull knobs used in airplanes for parking brakes, so I'm trying to devise something else.  I finally settled an a simple solution that is uncomplicated and functional.  I will simply mount the PV-1 parking brake where the normal brake lines bracket is and attach a handle to the lever that actuates the valve.  All the way up stowed under the instrument panel is released and all the way down is brakes set.  I'll paint the handle red on the side that is in view when it's set.  No control cables, no knobs.  I like it.

The following photos make it look large and clunky, but ... well, it is.  Still it fits my needs.  I made it from .050 and bent the edges for strength so that moving the PV-1 lever would not flex the bracket or the panel it's attached to.  No chance of that!

The space behind the instrument panel was already starting to get cluttered and I have hardly begun.  As I thought through what all had to fit back there, I decided to start moving things that could be moved.  It immediately became obvious that, with a bit of wire rerouting, I could mount the AP controller and Netgear ethernet hub behind the aft baggage ala the strobe power supply.  It would mean I would have to buy some more ethernet cables and learn to fit new plugs to the ends of Cat 5e/6 cables.  (That turned out to be a whole 'nother story).  So, I bought the tools and stumbled through rewiring some cables.  The ethernet hub is needed so I can use either EFIS to drive the autopilot.  In case of main EFIS failure or loss of main DC bus while in IMC, I want the ability to use the EFIS Lite to operate the autopilot.  Yeah, I know ... I'm planning for an event the odds of which happening are on the order of winning the lottery.  I'll sleep better.

24 Jun 06        4 Hours        Cum: 923

More work on the AP controller bracket installing nutplates and making a holddown bracket for the ethernet hub.

29 Jun 06        5 Hours        Cum: 928

Worked on fine tuning the AP controller/ethernet bracket.  There are lots of little things that have be done to make it fit aft of the baggage.  The size of the bracket is barely small enough to fit, so I have to carefully trim it.  Also, I have to mount it to the left side longerons which requires climbing in and out of the aft fuselage to cut and fit.  I should have it finished tomorrow.  Also, Yellow Freight is delivering my engine tomorrow from Barrett Precision Engines.  Photos to follow.

30 Jun 06       7 Hours        Cum: 935

Engine arrived today.  Mike Frijouf is loaning me an engine lift and the dynofocal mounts will arrive today from Van's, so I'll be ready to hang the engine this weekend.  I hope I haven't forgotten anything that has to be done before the engine is mounted.  I should still have good access to the firewall even after the engine is mounted, so hopefully I'm not making a mistake by hanging the engine.  I just don't have room to store the engine on the floor, so putting it on the airframe makes sense.