Came home tonight feeling like I've made a little more progress! In short, last two days about another 12 hrs working on removing old adhesive tape, removing and updating fuel injection airbox inlet, headlight and camera wiring, timing engine, engine breather routing, some interior, a new grommet through the firewall, checking fuse locations, checking header tank fuel status and relief routing and light wiring. I ordered a build placard a few days ago, N-Number decals, more firewall material and a few other items. I've narrowed down to two locations for my cockpit forward camera monitor. I'm getting very close to finishing with everything!
As I've said, almost everything is prototyped, tested, corrected then completed. I cut the grommet mentioned above six times before it fit correct in the firewall. It's amazing how easy it is to take a cabin heat cable, route it correct than after not looking at it for a while, rerouting because it looked incorrect than finding out why it was the way I first had it! Wiring and testing and fuel and testing...it all takes some time and focus. Steve and I did the timing on the engine over and over again, including the ignition, key switch and its timing. There was so many wrong ways to do it but we finally got it all right. We learned all about the magneto and it's impulse coupler.
We timed the magneto at 25 degrees TDC similar to the electronic ignition and it sounded really good. With Steve Alford observing, I started the glasair. It started within seconds of the key switch ON. It ran like a charm. I taxied around the east side of the airport to test the brakes and nothing was frozen, all worked very good. Engine temperatures all looked good but one connector to repair/replace on cylinder 3 that was fluctuating. It was another good finish.
Sunday, December 30, 2012
Friday, December 28, 2012
Log 69
It's been a cold week. Not much done for a few days. Today, Steve Alford and I flew for around an hour, then to the hangar to work:
- Started engine outside and tested a few issues. Proved correct positions on fuel switch, check. Found draining fuel in main tank was not from header tank but residual from fuel lines, check. Obtained a magneto timing light from Dan to time soon.
- Installed fire/heat insulation, lower cowling.
- Drilled hole in rivet (thanks Dan Thomas) for oil pressure fitting to engine to to limit hole diameter, in case of any future failure "Firewall Forward" book by Tony Bingelis, and per Chris Yeeles).
- Wiring and installation of monitor in cockpit, test and dialog with Steve.
- Started engine outside and tested a few issues. Proved correct positions on fuel switch, check. Found draining fuel in main tank was not from header tank but residual from fuel lines, check. Obtained a magneto timing light from Dan to time soon.
- Installed fire/heat insulation, lower cowling.
- Drilled hole in rivet (thanks Dan Thomas) for oil pressure fitting to engine to to limit hole diameter, in case of any future failure "Firewall Forward" book by Tony Bingelis, and per Chris Yeeles).
- Wiring and installation of monitor in cockpit, test and dialog with Steve.
Tuesday, December 25, 2012
Log 68 - Happy Holidays Everyone
I managed to get a little work done lately but mostly holiday time. Let me get to it:
Friday - Completed and submitted paperwork and files to the FAA representatives. I had submitted some previously but the individual moved on to a different job and I never heard back. I hope to follow up with them next week if 'in office'.
Monday (Christmas Eve) - Tail numbers, shopped around and ordered online. It's the best these days. New washers on wing to body shear web. Not per manual but these will be much stronger than spec. New control stick grips and fit check. That's it for now. A few new pics starting here .
Friday - Completed and submitted paperwork and files to the FAA representatives. I had submitted some previously but the individual moved on to a different job and I never heard back. I hope to follow up with them next week if 'in office'.
Monday (Christmas Eve) - Tail numbers, shopped around and ordered online. It's the best these days. New washers on wing to body shear web. Not per manual but these will be much stronger than spec. New control stick grips and fit check. That's it for now. A few new pics starting here .
Thursday, December 20, 2012
Log 67 - Weight & Balance
It's time for W&B. Dan Thomas let me use the RV club's scales made for weighing planes...simple scales and lever bars. Thanks Jason Yeo, coworker, for coming by to help. We put the cowlings on, flaps on, belly panel on for the first time, set all other fairings on the plane close to locations. Next, rolled the plane on the scales, leveled to waterline 100 so the tailwheel was about 4 ft. high. recorded each wheel and distances aft for wheels relative to engine firewall. This was all a great accomplishment. All done around 1000 lbs empty weight. Today's photos start around HERE .
Wednesday, December 19, 2012
Log 66 - December winter
Very cold time of year but winter solstice is close..time to celebrate. A couple days Cessna flying lately, my daughter's high school holiday concert, hockey, swimming and getting ready for the holidays are reasons to get other things done. My feet get cold through the hangar's concrete floor so I usually find a place to work off the floor and focus.
Chris Yeeles came by to view my project! Chris is another invaluable resource and instantly a friend, just like many of the builders and flyers I've met. Seeems everyone's intention is to keep each other as safe as possible. I'm so motivated to hear from people like Chris, who've already built glasairs and been enthusiasts for many years. His passion is like mine.
To note from a few posts ago, Ephraim recommended:
- Dynon fuel flow meter move to level....done, - tinnerman washers on wing/body bolt, check all controls for ANY loose parts, components or other awkwardness, - engine breather to exhaust system (acquire .6 od or 1.0 id short tube,
To note, Chris recommended:
-oil pressure fitting to engine to weld close and shrink the hole dia, in case of any future failure, - spacer oil line to cooler..done, - battery heat tape hot area, - safety wire exhaust spring (now not needed with secondary exhaust springs below), vent brake fluid resevour...done, - start an Airworthiness Directive (AD) long for all serial numbered parts on the plane, - trim seat pans for better access to center console (so far, not an issue but will check access with all interior parts in).
Besides this, have added control stick handles and ptt buttons, a few other items and obtained scales to do my weight and balance very soon. Dan Thomas and Steve Alford have been by recently to discuss a few of these issues. All's good and time to move forward again.
Chris Yeeles came by to view my project! Chris is another invaluable resource and instantly a friend, just like many of the builders and flyers I've met. Seeems everyone's intention is to keep each other as safe as possible. I'm so motivated to hear from people like Chris, who've already built glasairs and been enthusiasts for many years. His passion is like mine.
To note from a few posts ago, Ephraim recommended:
- Dynon fuel flow meter move to level....done, - tinnerman washers on wing/body bolt, check all controls for ANY loose parts, components or other awkwardness, - engine breather to exhaust system (acquire .6 od or 1.0 id short tube,
To note, Chris recommended:
-oil pressure fitting to engine to weld close and shrink the hole dia, in case of any future failure, - spacer oil line to cooler..done, - battery heat tape hot area, - safety wire exhaust spring (now not needed with secondary exhaust springs below), vent brake fluid resevour...done, - start an Airworthiness Directive (AD) long for all serial numbered parts on the plane, - trim seat pans for better access to center console (so far, not an issue but will check access with all interior parts in).
Besides this, have added control stick handles and ptt buttons, a few other items and obtained scales to do my weight and balance very soon. Dan Thomas and Steve Alford have been by recently to discuss a few of these issues. All's good and time to move forward again.
Wednesday, December 12, 2012
Post 66 on 12/12/12
A few days off since last post. Spent a few hours in the hangar today. Besides what I have narrated in the photos, I cleaned and chatted with my hangar mate for a short time. My list is smaller every day. I need to get busy on paperwork for final inspection. see photos starting at HERE.
.JPG) |
| One photo from album....12/12/12 - Just noticed how diaphanous the glasair is with a light inside. Had to take a shot. |
Sunday, December 9, 2012
Log 65 - Safety & other updates
Thursday Dec6:
Ephriam and Brad Walker come by to check out my project. Ephriam is another great resource and this is the first we meet in person. He worked at Glasair in the past, has been a test pilot, lots of tailwheel time, and is building a G2 glasair. He had a few points like adding Tinnerman washers in wing/body fasteners I'll do that. Also to check all control rods after rigging to assure tightness and engine breather to exhaust pipe. I want to ask my FAA representative about this technique and it is advisable Brad has been there a few times with me and will help maybe next week.
Friday (5 hrs):
Steve Alford comes by to help. We adjust rudder cables, stoppers including a new 3" section of cable and bleed brakes. One more bleeding will be required on left pedal. We measure and have full rudder deflections both ways, no interference from brakes/pedals to firewall or anywhere. All looks good. We install a new fuel line switch to firewall. New fitting firewall to boost pump.
Safetywise - I received a message saying someone saw my engine run-up from the airport and is contacting me to say, "no running aircraft in the hangar". I had the door open, main gear and engine outside and a fire extinguisher but have this to say. I asked a few pilots who didn't know that rule. IT'S SO IMPORTANT THAT ALL SAFETY PRECAUTIONS ARE TAKEN! Later, I found that airport operations had seen my video on log 59 . The postings in my blog help myself and others who read this realize it's safer to push the plane completely outside, out of the hangar. I've learned and others who read this will learn.
Safetywise - Reading in Sport Aviation magazine, article, "Defending the Future of Homebuilts", I want to learn more of a few non-mandatory items:
1. Function tests of fuel systems - assure I have a good system,
2. Find more technical advisers for the flight testing. - more info on flight training, transition training, knowledge of second pilot as a safety observer, flight test familiarity and documents needed, and use of electronic data recording during flight test.
Saturday (5 hrs):
A little more adjusting. Small break to Cessna fly. Tighten rudder stops, and install 5 of the most difficult cotter pins on the plane aft of the firewall. Brake/rudder assembly complete less new springs. Resin and mill fiberglass flap inboard ends on flaps.
Ephriam and Brad Walker come by to check out my project. Ephriam is another great resource and this is the first we meet in person. He worked at Glasair in the past, has been a test pilot, lots of tailwheel time, and is building a G2 glasair. He had a few points like adding Tinnerman washers in wing/body fasteners I'll do that. Also to check all control rods after rigging to assure tightness and engine breather to exhaust pipe. I want to ask my FAA representative about this technique and it is advisable Brad has been there a few times with me and will help maybe next week.
Friday (5 hrs):
Steve Alford comes by to help. We adjust rudder cables, stoppers including a new 3" section of cable and bleed brakes. One more bleeding will be required on left pedal. We measure and have full rudder deflections both ways, no interference from brakes/pedals to firewall or anywhere. All looks good. We install a new fuel line switch to firewall. New fitting firewall to boost pump.
Safetywise - I received a message saying someone saw my engine run-up from the airport and is contacting me to say, "no running aircraft in the hangar". I had the door open, main gear and engine outside and a fire extinguisher but have this to say. I asked a few pilots who didn't know that rule. IT'S SO IMPORTANT THAT ALL SAFETY PRECAUTIONS ARE TAKEN! Later, I found that airport operations had seen my video on log 59 . The postings in my blog help myself and others who read this realize it's safer to push the plane completely outside, out of the hangar. I've learned and others who read this will learn.
Safetywise - Reading in Sport Aviation magazine, article, "Defending the Future of Homebuilts", I want to learn more of a few non-mandatory items:
1. Function tests of fuel systems - assure I have a good system,
2. Find more technical advisers for the flight testing. - more info on flight training, transition training, knowledge of second pilot as a safety observer, flight test familiarity and documents needed, and use of electronic data recording during flight test.
Saturday (5 hrs):
A little more adjusting. Small break to Cessna fly. Tighten rudder stops, and install 5 of the most difficult cotter pins on the plane aft of the firewall. Brake/rudder assembly complete less new springs. Resin and mill fiberglass flap inboard ends on flaps.
Wednesday, December 5, 2012
Log 64
Brief: Since Monday, 6 hrs working on flap fit check/close out fabrication, moved brake line higher on firewall and cleared old fiberglass ribs which held rudder pedal assembly in old location. Thanks to Bill Jensen for flaring the ends of new fuel line to be installed from switch to firewall. Vacuum & cleaned foot area where I've been working. New photos start here on photo album.
Next: finish flap close out, find why fluid is in manifold pressure tube, bleed brakes again (passenger side has air), 2 person job to adjust rudder/brake pedals/assure full deflection.
Next: finish flap close out, find why fluid is in manifold pressure tube, bleed brakes again (passenger side has air), 2 person job to adjust rudder/brake pedals/assure full deflection.
Monday, December 3, 2012
Log 63 - Rudder Pedal Arrangement & other
I estimated 15 or 20 hrs on this rudder pedal assembly movement forward. It's continuing. Since last post, 9/24, I've spent about 3hrs/day+weekends=30hrs lately on everything. Milestone yesterday was to get in the plane, with pedals connected, seat bulkhead, rudder pedals/brakes assembled and feel the new configuration!! I want to say thanks to Brian Jensen, Jim Hoskinson and Kurt Hartzog for helping get a few tough bolts in. I still have to:
Smaller springs for pedals, test clearances/deflections (two person job) & adjust, cut out old rib supports with grinder, move brakeline on firewall, cotter pins, connect tension pedal stops already installed, and possibly grind right brake cylinder clearance as required.
Also in work, fuel lines, flap end closures/fit check and other work. New hangar heater works OK. Fuel line is done but pulled firewall to fuel switch, re-routed. Will install fabricated line when brakes complete.
Smaller springs for pedals, test clearances/deflections (two person job) & adjust, cut out old rib supports with grinder, move brakeline on firewall, cotter pins, connect tension pedal stops already installed, and possibly grind right brake cylinder clearance as required.
Also in work, fuel lines, flap end closures/fit check and other work. New hangar heater works OK. Fuel line is done but pulled firewall to fuel switch, re-routed. Will install fabricated line when brakes complete.
Saturday, November 24, 2012
Log 62 - Life in the Holes
About 5 hrs to pull the pedals/brakes out, about 10 more hrs through yesterday, to drill and re-align/re-assemble. There will be adjustments to the brakes as the geometry is slightly different but should work find Back to work now. Here is the hole I'm spending time in now.
Tuesday, November 20, 2012
Post 61 - Ripping Apart for a Purpose - Pedal Assembly
Do you call it "Going Backwards"? Today, I was thinking and that gets me in trouble. I spent hours thinking and moving rudder cable turnbuckles longer and just not getting the rudder displacement or pedal position and it was really bugging me. I pulled the manual out and found the pedal assembly position was temporarily in place when we installed it. It was for a smaller person and per the manual, could be moved forward. WAL LA! I was happy to read this but knowing it was almost impossible to get to some of the bolts. I tore into it today and removed the pedals and brakes! It was tough and took a few hours. It will take me twice as long to install in desired position but I am happy.
Today's DIS-assembly and other new stuff can be seen in the photos starting here . Another 24 hrs of work for the electronics/timing, mag timing, exhaust instl, tailwheel work and other things shown. Will be back at it tomorrow after work. It was all just a good idea.
Today's DIS-assembly and other new stuff can be seen in the photos starting here . Another 24 hrs of work for the electronics/timing, mag timing, exhaust instl, tailwheel work and other things shown. Will be back at it tomorrow after work. It was all just a good idea.
Sunday, November 18, 2012
Post 60 - Mini-Milestones
Let me start with the mini-milestones:
Manifold pressure: 4 hrs - From Engine to Lightspeed electronic ignition T'd to Dynon pressure sensor with correct lines and fittings. Use high performance auto similar system. Parts searching and a few hours climbing under the panel for routing and install.
Key Switch, Timing Magneto and Electrinic Ignition (EI): 2 more days - Seemed the timing was done but it was not for the magneto. The key switch was proving OK, but no sign of ignition from left magneto. We did mag ht tests, start tests, ground tests, impulse coupler tests. We started anyway. After start day and much testing for another Saturday, we found the magneto was 180 degree's off so the spark was not TDC for cylinder 1. We fiddled than found setting tool in 'right magneto hole' instead of left, then timed made the gear correct for the crank, and spark was close to where it should have been. This SOLVED our course timing and key switch issues. we still have to fine time the magneto but it should be easy.
Exhaust System: 6 hrs - 3 springs, holes in the fuselage, some sanding, isolation pads and the correct bolts to mount the pipes. Should be done.
Transponder Antenna: 4 hrs - time spent researching Garmin regarding must have a metal ground plane for a fiberglass airplane. They wanted 8x8 inches but space limited so fabricated aluminum plate to go over a frame. It's not flat and will have to ***(note to check later)*** test the transponder, right and left ~ 30 miles away to see if it is being received and no signal blocking from the exhaust pipe or anything. Antenna was too short on the threads, so buried within the fuselage, Bolted and sealed in place under panel fwd cabin.
Sealing the wing: .5 hrs - Around upper wing skin for noise, mostly for wind.
Reviewed header tank and a few more items. Kaisan Burst to lengthen cables to rudders at turnbuckes to give feet more room. It may work, will check today. 3 more hrs. I'm done writing now so back to the shop!
Pre-Engine start (days prior)
Manifold pressure: 4 hrs - From Engine to Lightspeed electronic ignition T'd to Dynon pressure sensor with correct lines and fittings. Use high performance auto similar system. Parts searching and a few hours climbing under the panel for routing and install.
Key Switch, Timing Magneto and Electrinic Ignition (EI): 2 more days - Seemed the timing was done but it was not for the magneto. The key switch was proving OK, but no sign of ignition from left magneto. We did mag ht tests, start tests, ground tests, impulse coupler tests. We started anyway. After start day and much testing for another Saturday, we found the magneto was 180 degree's off so the spark was not TDC for cylinder 1. We fiddled than found setting tool in 'right magneto hole' instead of left, then timed made the gear correct for the crank, and spark was close to where it should have been. This SOLVED our course timing and key switch issues. we still have to fine time the magneto but it should be easy.
Starting day was Nov 13th, 2012 on post 59 (see vid).
post start days
Tailwheel: 4 hrs - Pulled tailwheel to make notch for locked, going straight position. Other issues was, no ramps to allow spring lock to make tailwheel 'spin free' to forward aft lock (or take off and landing) position. I cut ramps on both sides of tailwheen assembly so it could 'ramp to' locked position while taxiing. Meanwhile, noticed tailwheel bearings were frozen after maybe 30 years. Tried greasing but no luck. Found a machine shop to quickly remove and will order or go to Kaman Bearing to check for more bearings.Exhaust System: 6 hrs - 3 springs, holes in the fuselage, some sanding, isolation pads and the correct bolts to mount the pipes. Should be done.
Transponder Antenna: 4 hrs - time spent researching Garmin regarding must have a metal ground plane for a fiberglass airplane. They wanted 8x8 inches but space limited so fabricated aluminum plate to go over a frame. It's not flat and will have to ***(note to check later)*** test the transponder, right and left ~ 30 miles away to see if it is being received and no signal blocking from the exhaust pipe or anything. Antenna was too short on the threads, so buried within the fuselage, Bolted and sealed in place under panel fwd cabin.
Sealing the wing: .5 hrs - Around upper wing skin for noise, mostly for wind.
Reviewed header tank and a few more items. Kaisan Burst to lengthen cables to rudders at turnbuckes to give feet more room. It may work, will check today. 3 more hrs. I'm done writing now so back to the shop!
Wednesday, November 14, 2012
Log 59 - First Engine Start, 11/13/2012
Just a video . More to come later. Thanks to Steve Alford for hanging around to help get a few things done tonight. A few minor bugs to work out but this is a big milestone.
Saturday, November 10, 2012
Log 58
Working towards First Engine Start. Last post, Oct 30th. I've spent a few days since last post, about 15 hours sewing contol stick boots, labeling switches/fuses, moving circuits, analyzing and labeling wires, preparing fuel system, and now ignition and other systems ready for engine start. Unplugged wire from SL30 to D180 so we won't see the COM Failure and no VOR head but its OK for now.
Today, Steve Alford and I moved forward on the electronic ignition, testing top dead center, cylinder 1, plugging in the hall indicator, sorting out the ignition switch, testing and installing, phasing the system by arching the cylinder 1 & 2 wire electrodes by moving the propeller at high and low spots. It was like awaking Frankenstien! Just need to install the 3/8" lines from cylinder 3, T'd to ignition and Dynon D180 for manifold pressure, and do fuel test, than ready for engine start. Maybe tomorrow!
More photos later.
Today, Steve Alford and I moved forward on the electronic ignition, testing top dead center, cylinder 1, plugging in the hall indicator, sorting out the ignition switch, testing and installing, phasing the system by arching the cylinder 1 & 2 wire electrodes by moving the propeller at high and low spots. It was like awaking Frankenstien! Just need to install the 3/8" lines from cylinder 3, T'd to ignition and Dynon D180 for manifold pressure, and do fuel test, than ready for engine start. Maybe tomorrow!
More photos later.
Tuesday, October 30, 2012
Post 57 - Radio Issue
Another 7 hours of troubleshooting...RADIO PROBLEM SOLVED! Glasair 88 echo tango was able to communicate with the tower for the first time! Radio, headsets, everything sounded good. One wire from the NAV RS232 connector is unplugged, needs to be traced to the Dynon D180 for the VOR head. I'll do that soon. Had two trips to Crown Aviation for bench test and discussion. Still a little work to do but it shouldn't be difficult. Chasing this issue of 'COM Failure' on NAV/COM display since June.
Thursday, October 25, 2012
#56
Cleaning up, fuel system, audio, radio for a few hours.
Today was my last day at work on loan to another organization. I spent a few hours after work on the glasair. I had time during the day to discuss the last fuel vent work with an expert or two. I was concerned that the vents exiting the fuselage in a location where, if an engine fire occured, the vents would try to ignite. The vents are very sturdy and unless they had fuel dribbling out of them, no fire could start. they're also far enough away from the exhaust to be safe. I'm no longer worried about this issue.
Regarding the radio, I tested the antenna's for resistance. Maybe not a problem but trying to solve the "COM Failure" message I've been dealing with on the radio. I've tried a few thing without success so far. Next may try to pull the radio and the wire set in back, and connect separately. I also unplugged the intercom but still the same message. I discussed with Andrey and Terry but no luck so far.
I found some music on my phone and realized I had a chord to plug to the music jack, so got my headsets out and tested. Tears for Fears - Laid So Low was the first to play on the glasair. It sounded good for a radio check. This is the first time I listened through my headsets. I tested both headset systems, both mic's, intercom; it all worked very good!
Fuel System: connected a drain to the header tank via hose to outside of plane and valve (which is temporary for first fuel test coming soon). Tightened all vent tubes and soon will tighten everything, mark and protect. Added a cover to my large instrument panel penetration so nothing can rub now.
Today was my last day at work on loan to another organization. I spent a few hours after work on the glasair. I had time during the day to discuss the last fuel vent work with an expert or two. I was concerned that the vents exiting the fuselage in a location where, if an engine fire occured, the vents would try to ignite. The vents are very sturdy and unless they had fuel dribbling out of them, no fire could start. they're also far enough away from the exhaust to be safe. I'm no longer worried about this issue.
Regarding the radio, I tested the antenna's for resistance. Maybe not a problem but trying to solve the "COM Failure" message I've been dealing with on the radio. I've tried a few thing without success so far. Next may try to pull the radio and the wire set in back, and connect separately. I also unplugged the intercom but still the same message. I discussed with Andrey and Terry but no luck so far.
I found some music on my phone and realized I had a chord to plug to the music jack, so got my headsets out and tested. Tears for Fears - Laid So Low was the first to play on the glasair. It sounded good for a radio check. This is the first time I listened through my headsets. I tested both headset systems, both mic's, intercom; it all worked very good!
Fuel System: connected a drain to the header tank via hose to outside of plane and valve (which is temporary for first fuel test coming soon). Tightened all vent tubes and soon will tighten everything, mark and protect. Added a cover to my large instrument panel penetration so nothing can rub now.
Wednesday, October 24, 2012
Post 55 - More fuel venting
Another few hours connecting hoses, testing parts, designing space, and squeezing in and out of the tight space. A few shots starting at here. really tight area. Next, to torque system closed, mark with inspection putty, protect by providing covers some places, then test fuel system.
Fuel Venting System worked 10/23:
Cut (4) 3.5" aluminum 3/8 fuel tubes from spool and straightened. Cut 45 degree angle, one end sanded/deburred. Cut (4) 3/8 penetrations in lower fuselage aft of firewall. Installed tubes & mill fiberglassed in place. Vent tubes will connect here. Also made internal bracket, fiberglassed inside fuselage for systems. Photo's next log. Exciting to get this part completed as I had to find best location for tubes to go external.
Cut (4) 3.5" aluminum 3/8 fuel tubes from spool and straightened. Cut 45 degree angle, one end sanded/deburred. Cut (4) 3/8 penetrations in lower fuselage aft of firewall. Installed tubes & mill fiberglassed in place. Vent tubes will connect here. Also made internal bracket, fiberglassed inside fuselage for systems. Photo's next log. Exciting to get this part completed as I had to find best location for tubes to go external.
Monday, October 15, 2012
build log 53
Taking credit. Nothing completed tonight was on my list directly but all had to be done. Moved fuel line to reroute electrical and systems. Cut larger hole in instrument panel for system, worked well, clean metal debri. Added a system/electrical bracket under passenger seat. Safety wired fasteners on roll autopilot servo. Reconnected fuel lines in final positions. Ready for fuel venting. More labels on panel and wires.
Sunday, October 14, 2012
Build Log 52
Found a good Soundstream VHR-72IRA display screen for my forward camera. Camera will assist in ground view for taxiing and will have a few other purposes. Tested system, installed camera and headlight in lower cowling. Worked on most of the electrical. Photos start here on the photo album. Radio pulled to get it bench tested.
Tuesday, October 9, 2012
Log 51
A few hours in the plane with Bill Jensen, fabricating three new fuel lines and installing. All looks good and fuel lines complete. Need to be tightened and tied down but lines are finished. See photos starting here on the photos website. Need to finish electrical, torque, mark and clean up before putting fuel in the tank.
LOG #50
Well, first log was Nov 2011. Now I'm up to 50. Celebrate (hoo rah) and keep moving.
Spinner closed & complete. Minor sanding edge of spinner clearance for prop complete. Cleaning & labeling of cockpit/instrument panel. Firewall aft: Started fuel line bending and connectors. Clearance hole complete & cleaned for one more fuel line/header tank. Wires bundled behind instrument panel. Pitot & static air lines hooked to instruments, labelled & complete. Aft panels installed to protect while climbing around in there.
Push to Talk switches & fuel line finish next. Hopefully find COM Error on radio.
Spinner closed & complete. Minor sanding edge of spinner clearance for prop complete. Cleaning & labeling of cockpit/instrument panel. Firewall aft: Started fuel line bending and connectors. Clearance hole complete & cleaned for one more fuel line/header tank. Wires bundled behind instrument panel. Pitot & static air lines hooked to instruments, labelled & complete. Aft panels installed to protect while climbing around in there.
Push to Talk switches & fuel line finish next. Hopefully find COM Error on radio.
Wednesday, October 3, 2012
Log 49
Prop/Spinner work:
Front Plate. I decide to fabricate from fiberglass instead of aluminum ..easier to cut and I have the plies made already and will mate to the inner fiberglass spinner well - Cut to size, fit check, re-cut, fit check iterate a few more times. Find washers, order/receive bolts with holes in heads for safety wires. Set blade pitch/each propeller blade using inclinometer. Loktite and torque propeller bolts, install front plate and safety wire. Fit check spinner for last time & start final spinner to back plate countersink and screw! A few more photos. See the Sept/October subheadings on the photos.
Also received order of fuel lines, fittings, fire extinguisher and a few fasteners.
Front Plate. I decide to fabricate from fiberglass instead of aluminum ..easier to cut and I have the plies made already and will mate to the inner fiberglass spinner well - Cut to size, fit check, re-cut, fit check iterate a few more times. Find washers, order/receive bolts with holes in heads for safety wires. Set blade pitch/each propeller blade using inclinometer. Loktite and torque propeller bolts, install front plate and safety wire. Fit check spinner for last time & start final spinner to back plate countersink and screw! A few more photos. See the Sept/October subheadings on the photos.
Also received order of fuel lines, fittings, fire extinguisher and a few fasteners.
Monday, September 24, 2012
Wednesday, September 12, 2012
log #47
19 new photos at the end of picasa album. Installed Whirlwind Composite ground adjustable propeller for the first time! Cleaned, measured and cut spinner preparing for installation. Many fit checks. Will require more trimming for exact fit. Goal to finish each step to prepare for engine start....no dates yet.
Tuesday, September 11, 2012
log 46
A few more engine stand off ties (hand tied fiber ties more reliable than zipties). Purchased another stepdrill, angle meter to check angles on each propeller, and more sanding brushes.Drilled and sized up (6) holes in spinner back plate perfectly and evenly spaced to fit on prop spacer bushings...worked perfect! Feels great to get this right. Soft installed back plate and propeller! Two layups fiberglass inside of spinner, 2" wide for countersinks at back plate. Finishing spinner. Obtained instructions from Whirlwind for prop torquing etc. Need to go to fire stations for old fireproof insulation front/aft of wing in fuselage. Searching for Halon fire extinguisher. ACS key switch schematic for electric ignition, ready to finish & check. Camera charger found so photos coming soon.
Monday, September 10, 2012
Post 45 - Status
Just an update of items to move forward, prioritized by next milestones (start, inspection, flight, flightest, after):
Sunday, September 9, 2012
log 44
I realigned my tasks and will show on the next blog. I organized by milestones: engine start, inspection, first flight, after (flight test and after). Currently working on spinner and propeller installation. First, to figure the task. With help today, I tuned the propeller to align for easy prop start if needed. To do this, had to pull the plug on Cylinder 1, and check compression (top dead center) for this cylinder than align the prop. Once complete, I marked and moved on.
The spinner backplate goes on before the propeller. I had to make a template to drill (6) holes in it. I drilled almost full size and need a bigger drill to finish (asap). I will also create a front plate for the spinner, cut and install! More later!
The spinner backplate goes on before the propeller. I had to make a template to drill (6) holes in it. I drilled almost full size and need a bigger drill to finish (asap). I will also create a front plate for the spinner, cut and install! More later!
Friday, September 7, 2012
log 43 late summer 2012
This week, working on the rudder pedal limiter. Glasair manual says to build up a composite structure off the firewall to the pedals. I started doing this and realized how difficult it would be and not a great design off the firewall. Started thinking tension instead of compression. I've built a cable/turnbuckle system that goes forward from the pedal cable arm (center console area) to tie in. Turnbuckles make it adjustable and accessible. Holes drilled and almost installed now. I will pick up the tumbler from the locksmith with new ignition keys today!
Friday, August 31, 2012
Log 42
Controls: I have knob/cables for cabin heat and air inlet flapper. The air inlet flapper is a red knob in the cockpit going to the air inlet box below the throttle body of the fuel injection. The mechanism is to allow pilot to manually open in case the inlet/filter clogs with ice in a very extreme case. I've mounted both knobs on the right of the panel, inlet flapper with a safety so passengers don't tamper but I can use it (airline pilot recommended). Cables routed and one attached to cabin heat lever forward of firewall. Otherwise, was working on the Cessna intercom and a flying last few days.
Tuesday, August 28, 2012
Log 41 - multiple small projects
Last post was July 10th. I've been working on many projects since then. Not many posts. My camera was down so not many photo updates. I took a small break for summer events.
Just a quick update:
Tailwheel lock: routed cable and cut to length, swaged. Revised lock pin on tailwheel. Cable routing design with pulley and overcam lever on panel. Cut slot in panel, installed lever arm, attached cable with designed cable stop/hold, lever displacement on panel - All Complete. Just need to label.
Stand-Off's for wiring installation firewall forward. Moved wires off engine mount and other places - mostly complete.
Rudder Pedal Stops - Moved from firewall compression design to tension cable design. Turnbuckles ordered and other parts ready to complete.
Comm Error on Garmin SL-30 and altitude encoding for Transponder - troubleshooting and hope to resolve soon.
More later...
Just a quick update:
Tailwheel lock: routed cable and cut to length, swaged. Revised lock pin on tailwheel. Cable routing design with pulley and overcam lever on panel. Cut slot in panel, installed lever arm, attached cable with designed cable stop/hold, lever displacement on panel - All Complete. Just need to label.
Stand-Off's for wiring installation firewall forward. Moved wires off engine mount and other places - mostly complete.
Rudder Pedal Stops - Moved from firewall compression design to tension cable design. Turnbuckles ordered and other parts ready to complete.
Comm Error on Garmin SL-30 and altitude encoding for Transponder - troubleshooting and hope to resolve soon.
More later...
Tuesday, July 10, 2012
Log 40
Today I had a chance to update my 'to do' list in excel since log post 24. I loaded 12 photos at picasa .
I connected autopilot pitch servo to the wing bus bar and cleaned up a few wires. Cleaning up wires means fastening down the bus bar and trying to make less of a mess of all the wiring installation, and keep it from rubbing anywhere, among other things like air hoses. Also safety wire and torque seal on wing body and other fasteners. More later!
I connected autopilot pitch servo to the wing bus bar and cleaned up a few wires. Cleaning up wires means fastening down the bus bar and trying to make less of a mess of all the wiring installation, and keep it from rubbing anywhere, among other things like air hoses. Also safety wire and torque seal on wing body and other fasteners. More later!
Log 39
Two more days and about 10 more hours of work. Network cable worked best with twisted pair wires to connect my pitch servo in aft fuselage to the wing bus bar, stripped wire, spliced, shrink wrap, locate and stabilize with wire sleeves. ELT coax and ends fabricated, installed and ELT tested...works well. ELT to panel ran. Wire ties everywhere, stand off dialog and will be needed for firewall fwd wires. Torqued and safety wired bolts wing/body. Closed out wingtips included 28 fasteners silicone through hole/connectors for wires in fwd position. More soon.
Sunday, July 8, 2012
Log 38
Summer days, its tough to write all the items accomplished lately when getting home late. I'll try a summary:
Enlarged systems tunnels, fastened down tunnels, holes in panel for fuel & other. Pedal stops-started, pedal springs on, lights marked and plugged, wing bus bar almost finished, coax for NAV, COM and Transx complete and installed. ELT wire installed, more aileron clearance and protectors modified. Wingtips on and need outside fasteners, wire install stand offs and silicone, oil overflow valve on, air clamps almost complete, sidewall brackets started, preparing tail wheel lock lever &fuel line. Safety wired ailerons & close counterbalances. Some painting on tips & exhaust. Fiber glassed cowling radius's to scoop, headlight bracket & wire route on. Software upgrade on Dynon and pins in connected/connected magnetometer. Other items if I can check my lists tomorrow.
First time to sit in the seat pan and check leg length...all good.
Need:
Electric standoff's firewall forward, finish side load brackets (3 plies each). passenger stick machine part, need ELT coax made, and everything else on my list to check tomorrow. Paint inside of cowl & find heat tape. Find why I have a COM error on the radio, why transx won't find Dynon altitude. Getting closer every day. Also update excel of hours and details spent so far on plane.
Enlarged systems tunnels, fastened down tunnels, holes in panel for fuel & other. Pedal stops-started, pedal springs on, lights marked and plugged, wing bus bar almost finished, coax for NAV, COM and Transx complete and installed. ELT wire installed, more aileron clearance and protectors modified. Wingtips on and need outside fasteners, wire install stand offs and silicone, oil overflow valve on, air clamps almost complete, sidewall brackets started, preparing tail wheel lock lever &fuel line. Safety wired ailerons & close counterbalances. Some painting on tips & exhaust. Fiber glassed cowling radius's to scoop, headlight bracket & wire route on. Software upgrade on Dynon and pins in connected/connected magnetometer. Other items if I can check my lists tomorrow.
First time to sit in the seat pan and check leg length...all good.
Need:
Electric standoff's firewall forward, finish side load brackets (3 plies each). passenger stick machine part, need ELT coax made, and everything else on my list to check tomorrow. Paint inside of cowl & find heat tape. Find why I have a COM error on the radio, why transx won't find Dynon altitude. Getting closer every day. Also update excel of hours and details spent so far on plane.
Tuesday, June 26, 2012
Log 37
Monday - Just to record more work from 4 to 11 pm:
Enlarged holes in rear spar of wing, and fuselage bulkhead for larger systems tunnel, installed larger tunnel. Cut out forward tunnel from wing to panel, but will need a second tunnel for air and coax. Cut two holes in panel for (2) fuel lines from fuel selector and system tunnel. Removed selector valve. Two more connectors on Strobe lights finally complete with new pins/connector modified for size (now just need power wires). Cleaned wingtip clearance for aileron counterbalances, a few coats of paint on elevator counterbalances & horizontal to fuselage join. Cut off passenger control stick...will make it removable. Strobe & ELT wire in aft tunnel run (now need COM coax, pitch servo wires & static air run from empennage).
Enlarged holes in rear spar of wing, and fuselage bulkhead for larger systems tunnel, installed larger tunnel. Cut out forward tunnel from wing to panel, but will need a second tunnel for air and coax. Cut two holes in panel for (2) fuel lines from fuel selector and system tunnel. Removed selector valve. Two more connectors on Strobe lights finally complete with new pins/connector modified for size (now just need power wires). Cleaned wingtip clearance for aileron counterbalances, a few coats of paint on elevator counterbalances & horizontal to fuselage join. Cut off passenger control stick...will make it removable. Strobe & ELT wire in aft tunnel run (now need COM coax, pitch servo wires & static air run from empennage).
Monday, June 25, 2012
Log 36
Someone asked, when will I finish?? I'm hoping this summer, but you never know. Maybe even early summer.....depends on focus.
Thanks
to hang glider pilots like Bill Jensen, Andrey Gusev, Steve Alford, Len
Baron, Paul Dees, a few others, my Boeing friends, my other flying friends, I've been moving along.
Sunday June 24th:
A few years back, I went to the Reno Air Races with no
idea I'd work on a glasair project. Bill Jensen and I went to the
glasair booth/Jeff Lavelle's pit location, got a free shirt and Jeff
signed it. http://www.glasairaviation.
Rodney Tong and Robert Grigson, RV8 and Long EZ owners came by for an inspection. Robert is an expert with the Dynon D180 system I have. We went over things I need to do for retrieving data and hooking up the autopilot servo's. I'll have to modify some pin configurations on the connectors for the NAV and GPS, and add another connector to the wires for the magnetometer. All parts are ordered...not too expensive.
Andrey and other friends came by to help and have dialog for the electrical system overview and a few connections. We did quite a bit of electrical system testing. We spent time with the strobe system and wiring. I've epoxy'd the light covers on the wingtips, cleaned up yesterdays fiberglass on wingtips and a few other items. Added intercom knobs... I'll be moving the plane better tomorrow for first time loading the hangar with two full airplanes.
Sunday, June 24, 2012
Log 35 - Wing/Body Join Milestone
June 22, 2012 Marks the wing/body Join.
First, thanks to Jim, Paul Dees, Len Baron and Dan Thomas for joining me for the plan thought up a couple days ago to join the wings to the fuselage! No way I could have done it myself. Everything went smooth. Jim and Dan are experienced airplane builders and all of us work at Boeing. There was some grunting and moaning but we got a plan, thought it out and got everything pinned in place and fastened. WHAT AN ACCOMPLISHMENT! It feels really good to get this done and timing has to be precise as once the wing is in, access is extremely limited in critical areas. It was perfect!!
Wing installed, (2) leading edge (LE) fasteners, (12) shear load fasteners on LE, (2) trailing edge (TE) fasteners.
Also, thanks to Nick Smith for helping to resolve rudder system deflection clearance issue (can be viewed in photos). Thanks to Kurt for Brake system check and other work.
Post wing/body join accomplishments: elevator push rod, trim wheel, cables, springs, electrical for lights, cables, systems tunnel clearance and fastened. Full rudder systems check, rudder deflection check/repair. Fabricated rudder stops, headlight/camera electrical bracket run, headlight mounting bracket, extra fiberglass on wingtip protectors for aileron counterbalance stay out area, and closed foam on systems center tunnel.
Another good couple days. When I find the keys on the shelves somewhere, I can have engine run up milestone, but a few other items to cover first. :)
Sorry to get carried away but over 30 photos added at the end of this album.
First, thanks to Jim, Paul Dees, Len Baron and Dan Thomas for joining me for the plan thought up a couple days ago to join the wings to the fuselage! No way I could have done it myself. Everything went smooth. Jim and Dan are experienced airplane builders and all of us work at Boeing. There was some grunting and moaning but we got a plan, thought it out and got everything pinned in place and fastened. WHAT AN ACCOMPLISHMENT! It feels really good to get this done and timing has to be precise as once the wing is in, access is extremely limited in critical areas. It was perfect!!
Wing installed, (2) leading edge (LE) fasteners, (12) shear load fasteners on LE, (2) trailing edge (TE) fasteners.
Also, thanks to Nick Smith for helping to resolve rudder system deflection clearance issue (can be viewed in photos). Thanks to Kurt for Brake system check and other work.
Post wing/body join accomplishments: elevator push rod, trim wheel, cables, springs, electrical for lights, cables, systems tunnel clearance and fastened. Full rudder systems check, rudder deflection check/repair. Fabricated rudder stops, headlight/camera electrical bracket run, headlight mounting bracket, extra fiberglass on wingtip protectors for aileron counterbalance stay out area, and closed foam on systems center tunnel.
Another good couple days. When I find the keys on the shelves somewhere, I can have engine run up milestone, but a few other items to cover first. :)
Sorry to get carried away but over 30 photos added at the end of this album.
Thursday, June 21, 2012
Log 34 - Upcoming Milestone, Wing Installation
Took a day off for flight of 2 to Chelan to drop off Steve's 172. He covered fuel but it was only 15 gal round trip, very nice evening flight after work.
Inventoried and prepared for tomorrow's wing join to fuselage. I've written a few people and hoping to have help tomorrow loading the wing to the fuselage. Anybody want to join us for ideas and help tomorrow? Contact me russlfboe at g mail com .
Current: pumped in brake hydraulic fluid, completed more connectors to wing bus bar. May items mostly complete. Sanded on fuselage....cowling parts, dorsal fin... etc. for hours. Went over design with Kurt.
Inventoried and prepared for tomorrow's wing join to fuselage. I've written a few people and hoping to have help tomorrow loading the wing to the fuselage. Anybody want to join us for ideas and help tomorrow? Contact me russlfboe at g mail com .
Current: pumped in brake hydraulic fluid, completed more connectors to wing bus bar. May items mostly complete. Sanded on fuselage....cowling parts, dorsal fin... etc. for hours. Went over design with Kurt.
Monday, June 18, 2012
Post 33
A few more days of work: Sized, cut, rosined tunnels on Rib A and wingbox for systems. Connected/set up wires for wing electrical. Have plans for auto pilot servo's and strobe lights. Cleaned shop and organized new shelves. New roller tray for fathers day.
Thursday, June 14, 2012
Post 32
Had a couple long days working on cowling seal, electrical, systems tunnels, canopy installation and a few other smaller items. Also did some fit checks and clearances of the cowling with the baffle gap seals. Some work included Brian Jensen and Nick Smith to check the project out and help with a few things. Great progress and planning lately. I hope to stay on a roll.
Again, photos chronological here.
Again, photos chronological here.
Tuesday, June 12, 2012
Post 31 - Registration
Just a quick note for another milestone. With a few tries since Dec 2011, I received my registration from the FAA today. It's been a long road but still traveling forward! I also got most of the engine baffling gap seal completed today. It is very custom and takes hours to size, cut, rivet and clean but glad its close to finished.
Photo link here in chronological order.
Photo link here in chronological order.
FAA REGISTRY:
Aircraft Description
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Sunday, June 10, 2012
Post 30 - Wing at Paine Field Now
Noting another breakthrough. My wing and almost everything is now at Paine Field. I was able to unload it off the truck myself and get it in. Wish I could weigh it but guessing around 450 lbs. It will be a chore storing and positioning in the hanger with my hangar partner.
Recent: cut plexi, installed and retained with fasteners. Organized.
Next: wires, headlight bracket, baffling finish, wire tunnels, fluidize breaks. On to rest of list.
Recent: cut plexi, installed and retained with fasteners. Organized.
Next: wires, headlight bracket, baffling finish, wire tunnels, fluidize breaks. On to rest of list.
Thursday, June 7, 2012
Post 29
Last 3 days have been very productive. Not lots of fabrication but with ideas and plans to fabricate and a few processes to move forward. Upper cowling access door and door surrounding: hinges, cut/sand/rivet/countersink/supports, heated to shape, refitted... all was good. Head/taxi light located fitted, hole cut and checked. Besides this, Aaron Rinn and Kurt Hartzog have visited and while explaining aspects of the plane, I've taken some notes, advise and information that will help complete parts of the project. We discussed the brake fluid and system, engine, instruments and all related electrical system. I'm looking forward to some short term work and not too far from installing the wing when I bring it to the hangar. I also have more lower cowling to be sanded and fiberglass checked and cleaned up.
Sunday, June 3, 2012
Post 28 - Organizing and starting to Roll Again
Since moving to Paine Field, I've had a cold and the weather turned good for flying. Not always easy to work on the Glasair. Once settled, I seem to roll and get a few things done. Today, Clico'd, located, drilled, countersunk and riveted the access door on. Cut out the hole complete and finished the top 7 Camloc 1/4 turn fasteners. Your welcome to view the last photos. Next, I need to form the door with a heat gun, and cut out lower cowling light and camera locations.
****In case there are any locals reading this, I could always use help and ideas. You can contact me to meet weekday afternoons or any time.
I also found a completed Glasair 1 on Youtube for your enjoyment.
****In case there are any locals reading this, I could always use help and ideas. You can contact me to meet weekday afternoons or any time.
I also found a completed Glasair 1 on Youtube for your enjoyment.
Tuesday, May 29, 2012
Post 27 - Moved Fuselage to Paine Field
Over Memorial weekend, I got a hangar to share and moved my fuselage via trailer from my shop to Paine Field. This is another step towards the end of the build. Thanks to my wife, daughter and sister in law for helping to load the fuselage and Steve Alford and Mark Drake for helping to unload at the airport! Today, Tuesday, I straightened, organized and started again on the access door on the upper cowling. I'll question some of my mentors on the next step of riveting the door...seems easy but I want it to turn out dandy.
Hopefully, the next few days, I'll have music, a little snacks and maybe some help from friends at work to relax at the hangar and work on the list of things to do! Very exciting. Just two more photos at the end of photos .
Hopefully, the next few days, I'll have music, a little snacks and maybe some help from friends at work to relax at the hangar and work on the list of things to do! Very exciting. Just two more photos at the end of photos .
Thursday, May 24, 2012
Post 26 - A little work at home
I know guys. Finally a little work and other post!
I took some time off to do other things for a while. It's good to have a change and get a few things done. It's not a race. I just want to get it done in a timely manner and still have fun. It was getting stressful trying to finish by spring, so I'm getting re-established.
Sure feels good to work on it again. I bought a few air tools, few more parts as you can see from the last photos in picture link also on the right of this blog . Working on the cowling but also measuring and fitting a few items. June, I'll move to a hangar at Paine Field, coming up quickly. Thanks for reading!
I took some time off to do other things for a while. It's good to have a change and get a few things done. It's not a race. I just want to get it done in a timely manner and still have fun. It was getting stressful trying to finish by spring, so I'm getting re-established.
Sure feels good to work on it again. I bought a few air tools, few more parts as you can see from the last photos in picture link also on the right of this blog . Working on the cowling but also measuring and fitting a few items. June, I'll move to a hangar at Paine Field, coming up quickly. Thanks for reading!
Monday, April 2, 2012
Post 25 - Another Move
I made a fairly easy decision to move to my house, the shop that I build with friends, to work on the fuselage more before finding a great deal on a hangar at Paine Field. I'll have about 40 hrs of work after the wings go on. The wings won't go on till I move to the airport. I'll get as much done as I can at home in the meantime.
This will save some commuting time, although flying some of the commutes was half the fun. The last post had some details, conservatively. I'll post more details later. Moving photo here and the next few pics at my shop, settling in.
This will save some commuting time, although flying some of the commutes was half the fun. The last post had some details, conservatively. I'll post more details later. Moving photo here and the next few pics at my shop, settling in.
Tuesday, March 27, 2012
Post 24 - A Turning Point
Ok, I'm at my next turning point on the glasair project. The current hangar I'm in is just too busy with income projects. We've been getting along great, but the income jobs are important to the owner so I have to find a new place to build and finish (divide and conquer). Next, I will either:1. move to my house shop, 2. move to another hangar at Arlington, or 3. Find a place at Paine Field. I need a new plan to finish the plane. I won't be able to put the wings on at my house, but its alot closer than Arlington. I need a place at Paine Field soon, than I can put the wings on when ready
(aw below=after wing)
I could use good idea's but my home is likely where to move for a short while.
This shows about 36 hrs of time of things to do after the wing, 171 hours total, very roughly:
(aw below=after wing)
I could use good idea's but my home is likely where to move for a short while.
This shows about 36 hrs of time of things to do after the wing, 171 hours total, very roughly:
| Project | time | when | info | |||||||||||
| cowling1 | 4 | sand the old air vent and finish/paint | ||||||||||||
| cowling2 | 6 | airscoop finish | ||||||||||||
| cowling3 | 4 | index pins | ||||||||||||
| cowling4 | 4 | headlight fixture | ||||||||||||
| cowling5 | 4 | camera | ||||||||||||
| electrical1 | 3 | wing lights to wing bus | ||||||||||||
| electrical2 | 4 | servo wing to bus | ||||||||||||
| electrical3 | 2 | headlight | ||||||||||||
| electrical4 | 3 | camera | ||||||||||||
| electrical5 | 5 | aw | all to panel | |||||||||||
| electrical6 | 5 | other - all connectors, other dynon | ||||||||||||
| timing | 2 | electric mag | ||||||||||||
| cable | 3 | radio, elt & trx to antenna | ||||||||||||
| fuel sys | 15 | aw | firewall aft, all lines, tests | |||||||||||
| air | 5 | pitot & static | ||||||||||||
| tunnels | 2 | 2 (light wires, servo, air.. ) & (antennas) | ||||||||||||
| trim | 4 | aw | trim set up | |||||||||||
| dorsalfin | 4 | finish sanding | ||||||||||||
| paint1 | 11 | fuselage | ||||||||||||
| paint2 | 3 | wing spots | ||||||||||||
| paint3 | 3 | interior - navy blue | ||||||||||||
| paint4 | 1 | engine touch up | ||||||||||||
| leather | 11 | interior | ||||||||||||
| brake fluid | 1 | |||||||||||||
| pedal stops | 3 | build fiberglass | ||||||||||||
| pitch servo | 2 | limiter & check clevis for clearance | ||||||||||||
| baffling | 4 | finish | ||||||||||||
| electric system | 4 | review and mark | ||||||||||||
| panel | 3 | labels | ||||||||||||
| placards | 2 | panel, px, experimntl…. | ||||||||||||
| cabin | 4 | feet box (2 under heels & 2 side panels) | ||||||||||||
| stick | 3 | handle, ptt & covers | ||||||||||||
| level & tow in | 4 | aw | ||||||||||||
| seat | 3 | underbuild, padding, seat belts & closure | ||||||||||||
| prop | 3 | install | ||||||||||||
| spinner | 5 | cut & install | ||||||||||||
| flaps | 11 | sand, instl, trim inbd | ||||||||||||
| door latch | 3 | & canopy instl | ||||||||||||
| calibrate | 5 | aw | Dynon system | |||||||||||
| fuse/wing fairing | 3 | aw | after flaps | |||||||||||
| transponder | certify | |||||||||||||
DAR walk grnd test |
everything |
|||||||||||||
| flt test | ||||||||||||||
| wheel fairings | aw=after wing |
Sunday, March 25, 2012
post 24 - Sunday
Today, I flew to Skagit Regional Airport. I had it planned to work on my Cessna at Oak Harbor but Tom was busy with Steve's plane so I flew back to Arlington to work on mine. Very nice day for flying outside.
Today, I finished re-mounting my autopilot roll servo and linkages to the controls. Glassed the inside and outside of the lower cowling to cover the old air intake and close the new scoop. Also completed the turnbuckles and Nico's on the rudder controls. I also got to put new main tires on my Cessna. That took a few hours, but glad to get it done. Also to mention, I ripped apart an old navy blue leather couch for it's upholstery. I will use it for the interior of my glasair. My wife helped me wash the pieces as well as clean the old masking tape off my canopy!
There's a few more photo's chronologically added at the end of the photo album. Link is on the right.
Today, I finished re-mounting my autopilot roll servo and linkages to the controls. Glassed the inside and outside of the lower cowling to cover the old air intake and close the new scoop. Also completed the turnbuckles and Nico's on the rudder controls. I also got to put new main tires on my Cessna. That took a few hours, but glad to get it done. Also to mention, I ripped apart an old navy blue leather couch for it's upholstery. I will use it for the interior of my glasair. My wife helped me wash the pieces as well as clean the old masking tape off my canopy!
There's a few more photo's chronologically added at the end of the photo album. Link is on the right.
Thursday, March 22, 2012
Short Post #23
I've worked out a few issues and still moving along. Not an easy job to sometimes design while fabricating parts.
The rudder cables were difficult to swage to length, so I ordered turnbuckles (arrived today). They will help for adjustments in the future and I noticed there are many airplanes that use turnbuckles on the control cables.
The throttle body and new air intake hung well below the lower cowling. What to do? Cut a big hole in the cowling and decide what to do later. OK, its done. Now, I show up after work, and someone found an extra air scoop in somebody's hangar! It's nice to have friends around. Now we have to match the intake with the scoop and its in work. Purchased more shape-able foam, glued it in place and already laying fiberglass from the cowling to the scoop. This is a big project but looks OK so far. Bill has help me with the foam shaping and sanding, along with two more fiberglass layers on the outside of the lower cowling to close the old air intake.
The roll servo for the Dynon autopilot has been temporarily installed but Terry didn't like the location. I'm in the process of moving it 1/2" lower and aft. It will be fine when complete. Brake system is complete and will put fluid in soon and bleed the system. Dynon replaced one of the servo's since I removed the shear pin while fabricating an attach plate that interfered....thanks Dynon!
Need to create two tunnels from the empannage for wires, antenna's and air for pitot/static system. Need to stabilize design for headlight, but have a few idea's. A few new pics in the album and moving along with some progress!
The rudder cables were difficult to swage to length, so I ordered turnbuckles (arrived today). They will help for adjustments in the future and I noticed there are many airplanes that use turnbuckles on the control cables.
The throttle body and new air intake hung well below the lower cowling. What to do? Cut a big hole in the cowling and decide what to do later. OK, its done. Now, I show up after work, and someone found an extra air scoop in somebody's hangar! It's nice to have friends around. Now we have to match the intake with the scoop and its in work. Purchased more shape-able foam, glued it in place and already laying fiberglass from the cowling to the scoop. This is a big project but looks OK so far. Bill has help me with the foam shaping and sanding, along with two more fiberglass layers on the outside of the lower cowling to close the old air intake.
The roll servo for the Dynon autopilot has been temporarily installed but Terry didn't like the location. I'm in the process of moving it 1/2" lower and aft. It will be fine when complete. Brake system is complete and will put fluid in soon and bleed the system. Dynon replaced one of the servo's since I removed the shear pin while fabricating an attach plate that interfered....thanks Dynon!
Need to create two tunnels from the empannage for wires, antenna's and air for pitot/static system. Need to stabilize design for headlight, but have a few idea's. A few new pics in the album and moving along with some progress!
Wednesday, March 14, 2012
Build Log 22 - March
I had three issues come up lately; the cowling airbox was interfering with the fuel boost pump box, so I removed the airbox. It wasn't in the best location anyway which is an excuse to move it to a forward facing air intake for the injected throttle body. The Glasair air intake was interfering with the throttle so I sent it back and ordered the Van's forward air intake. This was a solution for both mentioned issues. The Dynon roll servo is normally installed in the wing near the aileron control arm around butt line 100 (100" outboard in the wing) but the wing is closed. I will install under the seat, connecting to an aileron arm coupling.
Let me see if I can update relative to last log:
Completed lately:
Rudder cables moved build sequence in front of wing attachment. Cables with covers and end fittings installed but not adjusted. Injected throttle body air box received from Vans, and now partially assembled. I'm adding the optional air bypass flapper assembly including a cable. More sanding on the dorsal fin, canopies cleaned more thorough and ready to remove adhesive. New landing light tested and is very bright! Installed ELT remote switch on panel. Redesigned ELT brackets for easier removal from airplane. I designed and fabricated a bracket and location for the Dynon pitch servo for autopilot. It's now mounted in the empennage control tunnel connected to the elevator bell crank. It mounted perfectly and will test later. The servo arm displacement matches the bell crank movement so I am happy.
View the latest photos to see some of the progress.
Next:
Adjust rudder pedals in order to install rudder stops. Bring roll servo to Dynon to check shear pin. Fabricate/install servo limiter. Paint for white exhaust and navy blue for interior. Get old couch material for interior and glare shield and adhesive in place. Check clevis bolts on pitch servo for interference. Finish right brake connector & pack right wheel bearing. Air box complete. Cowling review for intake. Switch/breaker layout w/Terry AND create labels is in work. Cut/fasten spinner. Headlight system designed... need to fabricate. Two Empannage systems paths for static port air, strobe light power supply, radio, ELT and transponder antenna, Dynon trim servo wires. Lower cowling needs light cutout, camera cutout, air cutout and closure of old NACA inlet complete. Upper cowling (7) locks. Tail wheel fairing and main gear wheel pants at hangar for fit. Finish electrical connectors at wingtip lights, pitot probe, Dynon roll servo & bus bar under seats. Remote fwd camera needs cockpit display monitor. Sand and finish few spots on dorsal fin, horiz. stabilizer and lower flaps & lower cowling. Spark plug adapters? Electronic mag to be timed/installed. Paperwork for MIDO office, letter and receipt for FAA registry office has been submitted & needs to be checked. Tail dragger review at Harvey Field.
Again, my tail number on the Glasair is N88ET or eight eight echo tango. Battery to instrument panel and POWER ON complete!
Let me see if I can update relative to last log:
Completed lately:
Rudder cables moved build sequence in front of wing attachment. Cables with covers and end fittings installed but not adjusted. Injected throttle body air box received from Vans, and now partially assembled. I'm adding the optional air bypass flapper assembly including a cable. More sanding on the dorsal fin, canopies cleaned more thorough and ready to remove adhesive. New landing light tested and is very bright! Installed ELT remote switch on panel. Redesigned ELT brackets for easier removal from airplane. I designed and fabricated a bracket and location for the Dynon pitch servo for autopilot. It's now mounted in the empennage control tunnel connected to the elevator bell crank. It mounted perfectly and will test later. The servo arm displacement matches the bell crank movement so I am happy.
View the latest photos to see some of the progress.
Next:
Adjust rudder pedals in order to install rudder stops. Bring roll servo to Dynon to check shear pin. Fabricate/install servo limiter. Paint for white exhaust and navy blue for interior. Get old couch material for interior and glare shield and adhesive in place. Check clevis bolts on pitch servo for interference. Finish right brake connector & pack right wheel bearing. Air box complete. Cowling review for intake. Switch/breaker layout w/Terry AND create labels is in work. Cut/fasten spinner. Headlight system designed... need to fabricate. Two Empannage systems paths for static port air, strobe light power supply, radio, ELT and transponder antenna, Dynon trim servo wires. Lower cowling needs light cutout, camera cutout, air cutout and closure of old NACA inlet complete. Upper cowling (7) locks. Tail wheel fairing and main gear wheel pants at hangar for fit. Finish electrical connectors at wingtip lights, pitot probe, Dynon roll servo & bus bar under seats. Remote fwd camera needs cockpit display monitor. Sand and finish few spots on dorsal fin, horiz. stabilizer and lower flaps & lower cowling. Spark plug adapters? Electronic mag to be timed/installed. Paperwork for MIDO office, letter and receipt for FAA registry office has been submitted & needs to be checked. Tail dragger review at Harvey Field.
After wing installed:
- Fuel lines aft of firewall. Complete linkage between wing and rudder pedals, elevator trim system, and flap stop adjustments & pitch servo stop. Calibrate and multi-configure Dynon system (zero system, inclination and magnetic intensity). New transponder antenna needs to attach to lower wing panel cover. Flap clearance, Seat bulkhead then door latches. Contact FAA inspector for review. pg G-59 instrument side/feet panels & door latches.
Again, my tail number on the Glasair is N88ET or eight eight echo tango. Battery to instrument panel and POWER ON complete!
Saturday, March 3, 2012
Build Log 21
I've taking a small hiatus from writing but still progressing on the plane. Firewall forward (engine area) has been the focus lately. I'll try to catch up on most items here. For paperwork, I'm in the process of registering with the FAA. My tail number on the Glasair is now N88ET or eight eight echo tango. Still further to go for paperwork, but progressing. Some discussion with the local DAR from MIDO and I think it will all go well.
View the latest photos to see some of the progress.
Next:
Finish right brake connector & pack right wheel bearing. Air intake when part arrives & Cowling review for intake. Switch/breaker layout w/Terry AND create labels. Install ELT switch on panel. Clean masking tape off windows. Cut/fasten spinner. Headlight system designed... need to fabricate. Two Empannage systems paths for static port air, strobe light power supply, radio, ELT and transponder antenna, Dynon trim servo. OK Dynon trim servo with Terry and fabricate. Lower cowling needs light cutout, camera cutout, air cutout and cover old NACA inlet that was for carburetor. Upper cowling (7) locks. Tail wheel fairing and main gear wheel pants at hangar for fit. Finish electrical connectors at wingtip lights, pitot probe & bus bar under seats. Remote fwd camera needs cockpit display monitor. Sand and finish few spots on dorsal fin, horiz. stabilizer and lower flaps & lower cowling. Under seat electric bus& Dynon roll servo. Spark plug adapters? Electronic mag to be timed/installed. Paperwork for MIDO office, letter and receipt for FAA registry office. Tail dragger review at Harvey Field.
Throttle/mixture/heat cables complete. Throttle/mixture connected/finished at throttle body and instrument panel. almost completed baffling (pg G107) including holes and attachments. Fuel lines fwd of firewall complete. Dynon fuel flow transducer, oil and pressure and all Dynon probes complete. New ELT antenna installed. Oil cooler re-connected and lines re-routed. Designed locations and mounting of A/P servos. FAA issued tail# N88ET. Research HID headlight complete and at hand. Battery to instrument panel and POWER ON complete.
View the latest photos to see some of the progress.
Next:
Finish right brake connector & pack right wheel bearing. Air intake when part arrives & Cowling review for intake. Switch/breaker layout w/Terry AND create labels. Install ELT switch on panel. Clean masking tape off windows. Cut/fasten spinner. Headlight system designed... need to fabricate. Two Empannage systems paths for static port air, strobe light power supply, radio, ELT and transponder antenna, Dynon trim servo. OK Dynon trim servo with Terry and fabricate. Lower cowling needs light cutout, camera cutout, air cutout and cover old NACA inlet that was for carburetor. Upper cowling (7) locks. Tail wheel fairing and main gear wheel pants at hangar for fit. Finish electrical connectors at wingtip lights, pitot probe & bus bar under seats. Remote fwd camera needs cockpit display monitor. Sand and finish few spots on dorsal fin, horiz. stabilizer and lower flaps & lower cowling. Under seat electric bus& Dynon roll servo. Spark plug adapters? Electronic mag to be timed/installed. Paperwork for MIDO office, letter and receipt for FAA registry office. Tail dragger review at Harvey Field.
After wing installed:
- Fuel lines aft of firewall. Rudder pedal stops, complete linkage between wing and rudder pedals, elevator trim system, and flap stop adjustments. Calibrate and multi-configure Dynon system (zero system, inclination and magnetic intensity). New transponder need attach to lower wing panel cover. Flap clearance, Seat bulkhead then door locks. Contact FAA inspector for review.
Throttle/mixture/heat cables complete. Throttle/mixture connected/finished at throttle body and instrument panel. almost completed baffling (pg G107) including holes and attachments. Fuel lines fwd of firewall complete. Dynon fuel flow transducer, oil and pressure and all Dynon probes complete. New ELT antenna installed. Oil cooler re-connected and lines re-routed. Designed locations and mounting of A/P servos. FAA issued tail# N88ET. Research HID headlight complete and at hand. Battery to instrument panel and POWER ON complete.
Saturday, January 21, 2012
Post No20
Complete since last post:
Arlington airport is getting some attention airport but nothing new. I've got the control stick in place and completely hooked up to the ailerons, with rubber between all the rod ends and may be all attached for the last time before flight! This is some incentive to keep moving.
Smartsheet, a local spreadsheet company not associated with Microsoft has extended my account to let me finish the project. You may be able to find my project file on smartsheet.com . If you have any hints to be more organized, let me know!
I read an article regarding building good and fast and here is a summary:
****Any Comments? Let me know, thanks. I can use any help and appreciate the feedback*****
- Ailerons sanded/installed with counterbalanced on and cleared. Control linkages from aileron to control sticks are all complete. Aileron stops confirmed complete with full deflection. Routed air and electric through wing from center to Pitot tube 100" out at access panel. Emergency locating transmitter (ELT) bracket design upgrade on stowage panel. Installed Whelen strobe power supply below aft stowage compartment. Maybe last dorsal fin bondo. Elevator/rudder linkage cleared from stabilizer and counterbalance cleared from rudder (sanding). Empannage 2 bolts castlated. Brakes WIP (work in progress), design complete, fab 97% complete. Pitot instl wire run complete. Final sand/bondo dorsal fin. Battery installed in fabricated bracket. Closed wingtip lights. Cleaned out many items from original kit as 30 years, things have changed, move away from shop. Upper cowling cleared at new fastener locations. Purchased ELT antenna ebay & final brake lines. Installed instrument nuts on steam gages (airspeed, vert a/s, compass..), researched old notes and cleaned shop. New nuts on starter, some baffling on motor. Ordered missing seat belt shoulder straps.
- In shop: Finish last part of brakes, suppt bkt interface to wheel pants and new nuts. Per inspection, sand more elevator. Measure throttle/mixture/heat cable lengths. Prop/spinner cut/fasten. Finish baffling (pg G107). Install ELT switch on panel. Clean old masking tape off windows. sand flaps lower surfaces. upper cowling (7) locks. Research, bring tailwheel fairing and main gear wheelpants to hangar and start. Headlight system. Complete fuel lines fwd & aft firewall, Dynon fuel transducer, oilp pressure and all Dynon probes. Order transponder from spruce, attach new ELT antenna. Create path for Empannage systems (connect static port air, light power supply, radio antenna, transponder antenna). Finish electrical connectors at wingtip lights, pitot probe & bus bar under seats. Location and mounting of A/P servos.
- outside shop: Contact FAA for tail#'s again (lapsed timeframe for original number). If a reader has a good tail number for me, let me know! Research Remote fwd camera. Design & research HID headlight. Research windshield defroster (pg 522), removable glare shield (pg 333). Ask on forum regarding cheap but good headlight.
Decisions:
- Lower rudder hinge safety wire? Terry regarding wingtip electrical connector question.
After wing installed:
- Rudder pedal stops, complete linkage between wing and rudder pedals, elevator trim system, and flap stop adjustments. Calibrate and multi-configure Dynon system (zero system, inclination and magnetic intensity). Flap clearance, Seat bulkhead then door locks. Contact FAA inspector for review.
Arlington airport is getting some attention airport but nothing new. I've got the control stick in place and completely hooked up to the ailerons, with rubber between all the rod ends and may be all attached for the last time before flight! This is some incentive to keep moving.
Smartsheet, a local spreadsheet company not associated with Microsoft has extended my account to let me finish the project. You may be able to find my project file on smartsheet.com . If you have any hints to be more organized, let me know!
I read an article regarding building good and fast and here is a summary:
- Hit the shop running - Production time is not staring at the project - study outside the shop and research everything.
- Pre-visualize the work thats needed - have a plan each time you go to the shop to do and complete.
- Break down the tasks - The way to conquer the feeling of helplessness (yes, it happens often) is to forget that you are building an airplane, and concentrate instead on building airplane "Parts"! Just build the side body panels....forget about how complex the brakes may be. Or, break it down even further....just form a couple of flanges for the panels.
****Any Comments? Let me know, thanks. I can use any help and appreciate the feedback*****
Saturday, January 14, 2012
Log 19 - January, Friday the 13th
Storm moving in, might snow in a few days down to sea level. Flew after work - Paine field to Arlington for project, twilight flight to Oak Harbor, Whidbey Island and back to Paine Field. Since last post, I've flown two other evenings to Arlington this week. Not much work...I was down with a cold.
Complete:
Complete:
- elevators/stabilizer fastened, rudder/elevator/aileron deflection clearance finished. Horiz stab closed. Installed Dynon remote compass/magnetometer/bracket & located in place. Closed horiz stabilizer, attached elevator. Cut holes/riveted, glassed/installed static ports, installed Dynon ammeter shunt. ProSeal'd NACA inlets in place. Purchased AK-450 emergency locating transmitter, tested/ designed/fabricated bracket& installed. Delivered impulse coupler magneto (slick 4373) to Tom Downey for test/refurb at OKH.
- Elevator/rudder linkage clearance from stabilizer (sanding). Empannage 2 bolts castlated. Complete brake lines, pitot insl, run light wires, fuel lines firewall fwd & aft, Dynon fuel transducer & , sand/bondo dorsal fin more. Battery in bracket. Install ailerons after sanding & linkages. ELT switch on panel. Close wingtip lights & finish electrical connectors. Location and mounting of A/P servos. Clean old masking tape off windows. sand flaps & aileron lower surfaces. FAA for tail#'s again (lapsed timeframe for original number). Measure throttle/mixture/heat cable lengths. Prop/spinner cut/fasten. Finish baffling.
Decisions:
- Fuel injection throttle body control arm change not needed. Magneto impulse coupler to be checked/refurbed.
Way later (after wing instl, after all electronic fields established for some items):
- All control stops, rudder pedal stops, gap unit between wing and rudder pedals. Calibrate and multi-configure Dynon system (zero system, inclination and magnetic intensity). Flap clearance, Seat bulkhead then door locks. Need transponder & ELT antenna's. Remote fwd camera and headlight?
Monday, January 2, 2012
log18 - New Year 2012
January 1st & 2nd, 2 more commuter flights to Arlington Airport:
- More closing of elevators/stabilizer, started running new brake lines. Dorsal fin bondo, sanded, mill fiber resined bad spots..more sanding later. Ailerons hinges are now drilled full size, countersunk & riveted in place, removed by hinge for sanding with flaps - bondo'd. rudder, aileron, elevator deflection clearance finished. Horiz stab closed.
- Ordered Odessey PC680 battery, went to Dynon - traded low pressure sensor for HP sensor.
- Dynon Remote Compass bracket & locate in chosen place. Finish brake lines, pitot insl, run light wires, close horiz stabilizer, attach elevator to close all empennage. Install static port system, install Dynon ammeter shunt , Dynon fuel transducer & lines firewall forward, sand dorsal fin, sand elevator. ProSeal NACA inlets. Dave Wheeler for ELT. Install ailerons & linkages. Close wingtip lights & finish electrical connectors. Heater hose in cabin routing. Other idea's....I've got to figure that out. Location and mounting of A/P servos. Clean old masking tape off windows.
- Is one servo installed in wing? Remote fwd camera?
- No gascolator, no oil breather, no serial to parallel converter needed for transponder, no new safeair fittings for air system for now. ELT, just go 121.5mhz along with using SPOT.
- All control stops, gap unit between wing and rudder pedals. Calibrate and multi-configure Dynon system (zero system, inclination and magnetic intensity). more later..
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