Log 85

Milestone!
Glasair 1 TD, N88ET passes airworthiness inspection (pending paperwork).
More on this later.

Few things completed - few things to do before flight test.

I'll take a little break for an underwater hockey tournament this weekend, then back at it.
Photos start about here. 

I just want to say thanks to everyone who supported me with idea's, physical help, designs and knowledge along the way! There have been many of you!

log #84

Since last post, I've got all four piano hinges in on the belly pan and safety wired secure. Stowed and wire tied most of the wires for protection ready for flight including engine compartment and cabin, center console fasteners to pilot/passenger seats, closeout panels close including a new center console close out for the back fiberglassed and velcro'd in place. Have a new intercom decal but no intercom yet....bypassed and ready for flight at this time, new front camera ordered, registration mounted/laminated, four wing access holes double checked and closed, fire extinguisher mount fabricated and mounted on seat backrest, fabricated one stall strip (one more to be made), fuses labeled and generally cleaned out and ready for flight. My DAR was busy Saturday but hopefully the inspection will be soon. A few more photos, look for 2013feb photos at https://picasaweb.google.com/105540849251942747987/GlasairProject .

Log 83

Major milestone February 12th - avionics certification complete! Instrument application tested is best described here. Tested pitot and static air systems, transponder, altimeter, vertical speed indicator, airspeed indicator, encoder and redundant systems of each on the Dynon flight deck. The Dynon flight deck has most of these, and I have analog backups.

Belly pan is installed but piano hinges need to be driven in fully and secured...will be working on this. PS Engineering, PM2000 intercom I got used has failed. I need to replace but meantime, made a jumper so the pilot is hooked up mic and headphones to the radio in case of first flight before a repaired or replaced unit. All else is going good. I chose to fly with Steve yesterday after work instead of moving forward on the glasair.

Log 82

Just to log a few completed items from part of last week till today, approx 14 hrs:

1. Finally a chance to review, test, install and start calibration of my fuel sensors to the wing and header tanks, electrical power and to the flight deck.
2. Tested wires! Had some auxiliary wires made for remote access for updates to the Dynon flight deck. Soldered new to the VOR, closed the EFIS connector DB25 with corrected wires and one mystery wire to the correct pin location (I had disconnected earlier for testing). Wire into Pin#20.
3. Finished air hoses. S/b ready for Tuesday's cert. Slightly modified for more direct air.
4. Cleaned and fiberglass resin on old rudder/brake pedal supports removed.
5. R&R'd fuel in main tank while fixing a small leak at the feeder connection. Sanded burs on fitting and more direct to connector. Seems to be no leaks now.
6. Cabin heater cable more direct and tightened.
7. Finished all other firewall penetrations, one with firehose/clamps and others with bolts.
8. Started stall strips. Created full mold ready for mill fiber/resin.
9. Safety wired oil spout tube to engine, more baffling bolts with castle washers, complete.

Few things added to list after Miles came by for quick review. Some items listed above, also will look at Van's brake fluid breather valve, bend cotter pins away from mechanic access, tighten alternator belt/safety wire, RTV around baffling for better cooling and remove duct tape from airbox....added these to list of things to do.

Log 81

That's right! As they say in Turkish, Seksen Bir! ...that is 81. Today, unsuccessfully tried to certify my transponder/altitude encoder. I learned a few things but my air lines were not tight yet on the instruments. I went back to the hangar and had them all tight by the evening so its not a big issue. For me it is still emotional to think I had such a large setback that could take months to resolve but it took hours. I feel very fortunate with most of the work I've accomplished.  More later.

The sun came out just long enough to get the shots above.

Log Post #80

Another extraordinary day with the Glasair. I had been sick with a little stomach flew and found out that my planned DAR was leaving town for 3 months so he couldn't inspect my plane per part 21 for my airworthiness certificate, but that's only the bad news and not much of it. I have to say, its been a pleasure staying in touch with designated airworthiness representative (DAR) Charlie Cotton over the last year +. I will have to find a new DAR.

On the good side, it was 50+°F outside today. Good day to have the hangar doors open, working. Tightened fuel lines for final time at main tank, cut seat pan so I can get the seat pan in while the back rest bulkhead is in place. Cleaned, cleaned cleaned. Set alarms, indexed, and calibrated the Dynon D180 flight deck mostly using the original Stoddard Hamilton prototype operations manual. Seat belt fit check again after small modifications in seat pan.

Once this was all complete, put a gallon of fuel in the header tank, gallon in the main tank and taxied to the Regal pumps for 7 gallons in the main tank. On the way over, a small discussion with paine ground to test the radio's in low traffic. They could hear me very well. Taxied more on way back. Picked up Steve and we taxied across the airport to the compass rose, to calibrate the analog compass and the D180 flight deck. All went very cool, very good.

Things to check after this adventure:
1. Plane seems to like starting off header tank or more than a gallon in the main tank....have to test main tank at low level more.
2. Make some headset holders....I have a place now.
3. interior lighting not great.....will work on this.
4. lighted switches don't always work....add to electrical working page.
5. door lock ergonomics....will modify locks later and grease the sliders.
6. interior fitting cover missing....will look outside hangar tomorrow.
7. Check pitch on D180...it may have reset will not level to waterline 100.

Another good day. I will prepare for my electrical cert set for February 5th. The list of things to do is getting smaller.