log 79

Another amazing time while working on the glasair project. Between all the discussions getting ready to get sign off inspections, electrical cert and others, I went to Arizona to visit family and friends, and get a little tailwheel training at Chandler Air Services in a Piper Super cub. The super cub isn't exactly like the glasair but any tailwheel training is good, and flying with Matt and Clark taught me a few new things and good practice. Sorry to the friends I didn't get to visit down there.

Besides this, about another 12 hours working on the glasair:
Safety wires and provisions on flaps, complete. Flap linkages, complete and checked. The compass is not required for experimental VFR but I added a data plate to calibrate it once flight test is started. Had to cut a few special screws for the compass. Completed the door latches, both sides finished. Firewall penetration is closed for large hole. I will have to do the others also. Header tank drain valve redone to make more permanent and in a good location. New photos starting here in the photo album.

Log 78

Today, my coworker, Erdal Bayseckin, joined me for some 'two person work'. Takes two to move the flaps around while installing the hinge pins. There is very limited space and all the angles are wrong to get them in. We got all (4) of them in place and ready to secure in a couple hours.

Today, the paperwork checked out good by the FAA and is now delegated to the DAR inspector. Timing and schedule are now a little critical but I won't push it. 

Next post may be in a few days. I'll be taking tail wheel lessons again in a supercub in AZ.

Log 77

Cessna flight at noon today. First day for a while with little fog at the airport.

Afternoon, worked on glasair for a 2.5 hours. Cut holes, made up some resin/fiberglass and installed inserts for door latches, both sides. Cut new handles for latches, both sides and will install when all is cured.Used extra resin for upper cowling access door supports I was planning to create, now complete. Installed canopy handles. For photos, see photo link on last post.

Log 76

Another few hours wire troubleshooting, nothing there yet. Pitot tube fitting complete and installed. Plans for canopy lock inserts. New key lock today, pilot side only but installation later. Tested electrical to main tank fuel sensor....more test to understand this.

Will research inserts tonight. Going to AZ in a few days for some tailwheel training. Have possible new test pilot set for first flight or in discussion. Discussed with FAA representative for tentative plan and priorities toward airworthiness plan. More later. A few more photos starting around here.

Log 75

The last log noted the success of troubleshooting electrical issues/wires till the D180 flight deck encoder talked to the transponder to show altitude. I discovered this problem in June and wasn't able to resolve the problem till last Monday.

Since Monday, I've spent about 12 hours troubleshooting more wires for interior lights, VOR, soldering push to talk (PTT) switch and headphone jacks, routing wires, appointment for transponder/encoder certification, fit checking lower cowling, discovering fwd camera monitor needs work since camera view is backword like a rear pointing camera, checking control fittings for anything loose, checking piano hinges for flaps and other areas for safety and a few other items. I've also been planning further fuel system testing, flight testing, calibrating the D180 flight deck and setting flight perameters like V speeds, tachometer, fuel, pressures, flows and other alerts. I have a small issue to resolve for the intercom so will be working on this again, as it worked fine up till recently while moving wires.

Log 74 - Electrical Troublshooting (part 2+)

Thursday, Friday and today, another 10 hrs on electrical. Photos have helped since its so difficult to see wires while traversing under the instrument panel. I've got better at it. It can be very difficult to tackle wiring, chasing and trying to focus on just one issue at a time, also wondering which end of the wires to start at. I'm getting a little better. The best ideas are while waking up the next mornings before getting out of bed, recalling another wire I had seen and thinking its part of a solution. It's all working. Tonight was the first time I've had the transponder pick up the altitude from the Dynon D180 flight deck encoder. At the same time, I had the VOR started and it was asking for a GPS to get data from. (Note, to make a toggle for the remote GPS). It will be saved for later. Some photos starting here in the album. It was snowing outside, the hangar was cold, I had the canopies closed with a lamp and it was fairly warm inside.

I had some wiring help previously and there was a few small mistakes. I'm learning what needs to be connnected to the Dynon and how. I found a small wire bus used to convert a few wire colors and able to trace a few back to their sources. Had the transponder out and finally found wire pin #9 which should go to Pin #13 on the dynon. It worked. Pin #5 on the SL30 VOR goes to the remote update plug which goes to Pin 22 on the dynon. It goes here because it needs to be unplugged for dynon updates, and, to unplug while plugging a remote GPS. It may not need a toggle and I must find this out from Dynon, or test.

Log 73 - Electrical Troublshooting

Yesterday, I tried without success to find the error in the wiring by checking continuity from NAV/COM and transponder to Dynon D180 flight deck. Today, I took Brian Jensen after work and we solved one of the problems. A few wires were incorrect between the three instruments and we know they are. Tested connectors and after Brian left, I temporary rigged some wires and wha la.....got the Dynon to get data from the NAV/COM! It was snowing so left early after an hour or so.

Log 72

Winding down trying to recall what I did last day or two since last post. Saturday, did a little cessna flying with friend while the weather broke. After I worked on video camera/monitor and headlight about 5 hrs. Ran wires, tested on fuses, tested more. Found permanent location/mounts and assembly for video monitor. Sunday, no work on plane....just watched Seahawks win their first playoff game of the season.

Tonight, Monday after work, monitor mount more angled adding shim and sealing. Sealed fuel injection air duct, fabricated duct tube ready to secure and check against cowling, changed center wing/body bolts to clear control stay out area by turning bolts outboard...much better. The bled brakes for the last time hopefully! Clean and went home to cut a woman's coat up to make stay out panels...they'll be velcro'd in place behind the seats to keep foreign object debri (FOD) from areas I can't reach. Time for bed.

Oh, new photos start here .

Log 71 - January 2013

Since last post, I've had a list of small items completed including fasteners and close fuel HP boost pump airbox, electrical for landing light, camera, monitor, graphics, labels and required placards, more heat shielding, engine breather to exhaust secure, testing electrical systems, FAA coordination, riveting new firewall grommet and other items. I added this 3 view modified from another glasair to fit my dimensions and configuration.....kind of cool! I've been at the hangar last 3 days, 4 hrs/day. Next list of items are mostly troubleshooting, than fabricating. More photos starting about here in the photo album.