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.
Wednesday, December 5, 2012
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.
Subscribe to:
Posts (Atom)