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.
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