Wired up mate-n-lock connectors for the AFP fuel boost pump.
No Pics
12/9/2007
8
Today was one of those days where you have to spend time reading and researching. (All you builers out there know what I mean....) I tinkered with the wiring some and did a few small jobs. Finally I decided to install the fuel boost pump. I had to do some trimming to get everything to fit. Then I cut, bent and flared the main fuel line.
Engine arrived! Lycoming I-360, fuel injected, two slick mags (1 to be replaced by the Lightspeed IGN), CS Prop. (already here). I'll be hanging the engine next Sat.
Spent some time troubleshooting the compass on the Dynon EFIS. I narrowed it down to no power on one of the pins on the DB9 connector. I good conductivity and that is what has been puzzling me. I finally pulled the pin from the DB25 on the EFIS side to check power and there it was, 12V. It had to be cable. I disassembled the DB96 and found the guy from Gulf-Coast had wired the power lead to ground. .... that's no bueno... dead short! I re-rigged the cable, cleaned up the mess and can you believe it, the compass started working. Some engineer at Dynon did his due diligence. I would have thought I'd be shipping the unit back for a repair.
Installed LEDs for the EBuss. I had to change the switch out to a DPDT. This allowed me to use the other side to drive the LED. I wanted the amber LED on when the EBuss was pointing at the battery. In truth it could be pointing at the battery always but I will probably run it off unless Im in an necessary override condition.
No Pics
9/9/2007
8
Began fabrication of the mag compass bracket. I used brass screws and nuts to mount it.
Spent time on the avionics wiring. I finally got the Dynon hooked up to the GPS. I did some clean up on the wiring etc. too. Much of the time spent was researching/reading the install manuals to determine how I could make all this work.
Labor day. I plan to do a 3 day "builderama" over the holiday. Mike Stansbury came by this morning and we talked through his electrical system design and finalized his parts list. He's building a great RV. It's going to be almost as good as mine... LOL! (NR). I spent the rest of the afternoon working on the cablin lights.
I spent the morning messing around with the Dynon EFIS. I figured out how to program the screens, change the layout and order in which the display. In the process I did a bit of testing of the electric system. Everything is working great.
Began the Dynon harness wiring. This is where most of the sensors come into the EFIS. I had to decide where to penetrate the firewall WITHOUT the engine being here yet. (It ships Sept. 11, 07). Next I had to sort out the wires and do a lot of reading to get there. It was time consuming.
The propeller arrived today, Hartzell constant speed. Sweeeet! I spent time wiring up the strobe lights to the power supply and tidying up the wiring down toward the tail section. I knocked a 1/2 hole with a greenlee punch for a snap bushing going aft. This will be for the strobe and nav lights in the rudder.
I worked on the landing gear today. It turned out to be more work than I anticipated. I had to dismount and remount both tires two times (had trouble with one valve stem). Match drilled the brake brakets, engine mounting brakets (gear only), then got the right gear put together. Mike Stansbury came by and we talked RV's for two hours. He lives right here in Franklin and is building a RV 7. Small world.....
No Pics
8/1/2007
3
Installed last spike catching diode, main bus power cable, installed radios, Air gizmo dock and reinstalled the DigiFlight II AP
I finally riveted on the Dynon mounting tray. I had to remove all of the steam gauges to get to some of the rivet locations. Next, I slipped the Flight Deck into the tray, hooked up my bench power supply and powered it up. Pure ecstasy.....
Completed wiring of the dimmer panel circuit, wired the fuel boost pump switch and circuit, changed the GMA 340 mount, mounted terminal control strip for Pilot stick.
No Pics
7/15/2007
8
My air speed indicator finally came in from Chief Aircraft. I managed to get it mounted. I had to enlarge the punched hole slightly with a sanding wheel while it was in the panel. I installed the control bracket, the prop and mixer control. This included penetrating the firewall and installing two eyeball grommets.
Today was an odds and ends day in the shop. I completed the final wiring runs aft for the cabin and map lights and also the aft navigation light that will mount on the rudder bottom. Then I spent an hour tidying up the electrical wiring in the forward cockpit.
No Pics
7/7/2007
0
The quarterly fly-in out at John C.Tune airport.. (My airport now, hanger 304, once I move the plane there). Anyway, there are some good photos of some experimental aircraft, including RV's
Worked on the flap circuit design. Basically the switch setup (ala Uncle Bob) is working great. I'm going to add some limit switches to break the circuit on each end of full travel. I just have to figure out how to mount it. Another elec. order arrived with my term. strips, LED lamps, and some LED's I'm going to use as annuciators.
No Pics
7/5/2007
3
Drilled and mounted the headset jacks (Pilot and Co-Pilot), wired up the flap switch and motor. I hooked up my bench supply and ran the motor up and down a few times. Nice to see some things starting to come alive in the cockpit.
No Pics
6/24/2007
8
Very productive day in the shop. Terry Daily came by and worked on the elevator fiberglass tips. I worked on the panel most of the day. I completed a bit of filing, scotch brite pad to rought up the finish for priming, primed and painted the panel. After drying for several hours I mounted all the inistruments I had and switches. I also mounted the tires on the wheels (while the panel was drying) and after dinner did a bit or oganization and started the wiring.
Today I spent some time organizing the shop a bit. I finally bought some 4 oz. containers to organize my rivets, they were getting out of control. I swept the floors, cleaned off the benches yada yada yada. I finalized the panel, I had to drill two additional switch holes in the panel. I did a bit of test painting and finally chose a color and style. Then I read in the plans a bit and made the decision on the throttle, prop and mixture control placements and drilled the holes.
Spent most of the day finishing up the panel. Cut and filed the hole for the Dynon D-180 FlightDek EFIS, matched drilled for the AP mount, circuit breakers and drilled the trays for the avioncs stack and GPS to the panel rack. I also picked out my lighting but have to order that.
Spent a few hours drilling the last 6 switch holes in the panel. I drove out to Harbor Freight and bought a set of Tungsten (29pc) twist drills. I needed the 15/32 to drill the holes. I picked up a few other items like diamond needle files, 1X30in sanding belt and 5in sanding disk. My others were "worn out".
In addition to reading ahead in the drawings to figure out my next move today I mounted the three fuse buses to the forward fuselage. I'm using a modified version of Bob's Z-11. I will have one left mag and one electronic ignition module (IGN). Since my Dynon and 496 Map both will have internal batteries they will not run on the EBuss which has 10 circuits. If I loose the alternator they will run for hours on their own batteries. So my MBuss has the 20 circuit fuse buss, the BBuss has 6 circuits.
Today I mounted the turn co-ordinator and then drilled 4 of the holes for the lighting switches. The avionics stack holed required a bit more filing to get it just right.
Match drilled the F-703C end angles and riveted to the panel. I spent the rest of the time finishing the Altimeter and VSI cutouts, drilled and mounted them. The panel is coming along.
Took off from work today to wait on my avionics order and my electrical order from B and C electric. After FedEx arrived with the avionics I immediately went to work on the cut out for the avionics stack. Also used the instrument hole punch and knocked out the 4 major instruments holes. (Altimeter, air speed, vertical speed and and turn co-ordinator)
I spent several hours today going over the fuse assembly plans and the firewall forward plans trying to get an idea about what to do next. I finally decided to spend some time laying out the control panel which now I'm glad I did. I've been mulling this over for months and when I finally layed everything down it went in just right. Late in the day I decided to permanently rivet the forward fuselage structure on. Now I'll have something to begin mounting the electrical system to.
Great day in the shop but hot. Memorial Day weekend was a warm one. Mounted the control panel angles. It was very tricky.... lots of match drilling. Completed the right and left cabin vents, fabricated the forward control cable bracket and riveted one of the canopy latch hinges that came with the fuse kit. Believe it or not, along with studying the plans some more and a bit of shop cleaning that was the whole day.
Today I trimmed the aft most elevator horn. It was striking the aft tail cone bulkhead before striking the up elevator stop. The smart tool came in handy here. I disassembled the elevator connection and measured the deflection of the forward horn and then dropped a line on the aft one (now on the bench) to match the degree angle of the other. The hacksaw did the rest. I spent time studying the electrical schematic sent from Van's for their wiring harness. I am using a Z-11\Z12 variant and need to retro fit the harness to the Aero Electric schema. I also fabricated the master and starter relay copper bar and mounted.
Final install on the rudder pedals. I actually tightened the fittings on the master cylinders a full turn (1 full rotation) and made sure there was enough fuel lube. I also tightened the Banaco hoses leading to the fire wall.
Drilled and squeezed all the rivets on the F-781 VS bracket and permanently mounted to the fuse (I hope at least). I then adjusted the rod end bearings on the rudder and hung it (for the first time!) to check clearance. It was perfect using Van's dimensions.... no binding whatsoever. I also mounted the adel clamps for the rudder cables at the rear fuse.
Painted the tail wheel spring mount and finished drilling the mouse hole on fuse bottom. Cut 5/8 inch off the VS front spar. Also, the new flaps arrived from Van's so I unboxed them and boxed up the RV-8 flaps they sent by mistake.
Drilled the mouse hole for the tail spring assembly and test mounted the horizontal stabilizer.
No Pics
5/4/2007
2
Adjusted the rod end bearings on both elevators, temp mounted them to the horizontal stablizer. Made a drill bushing and drilled the HS hinge bearing holes in both control horns.
No Pics
4/29/2007
8
Finished up the fuel vent lines and fuel lines. Terry made shims and we blind riveted the air vents onto the fuse.
Match drilled and mounted the strobe light power supply bracket. Terry Daily helped with the riveting. It took two people. I also finished mounting the pitch servo and bracket.
I didn't get much done on the plane the last few days. The heat pump went out in the house, busy at work etc. A very good friend of mine (Beth Cooper) did come up and say hi and check out the project. Beth and I go way back. (5 years now I think?) She loves to fly too and has promised to go up with me once everything is certified and ship shape. 8^)
Finished the fuel boost pump. Removed the cabin frame and tapped countersunk holes with 8-32 tap for screws. Removed the rear fuselage skin. Prepped the cockpit for setting wing incidence and sweep.... the scary part. 8^)
Assembled the upper forward fuselage ribs and frame. Then I clecoed on the forward skin and match drilled all the holes. I had assembled the ribs incorrectly at the bottoms of the F-768B-R and L. It was preventing the skin from matching up just barely on one end. I disassembled and found the problem then re-assembled.
Awesome day in the shop today. I finished the remaining chores on the cabin frame. Namely angle brackets, matchdrilling the F-732A spacer then deburred and primed everything. At 10:00 Brett Lanham (buddy from work) came by with his cub scout troupe and we did a field trip on how to build an airplane in your garage! (see pics). After that I matche drilled the F-774 aft fuselage skin. There was interferance with the two longerons at the top (from the QB factory) and the holes wouldn't match up to drill throught bulkhead. I had to remove the skin and grind them down. After that I finished match drilling. I also began assembly on the front deck ribs and fabricated some of the angle brackets, F-741C and F-741D.
Temporarily mounted the F-774 skin and match drilled the F-732A channel and F-732 spacer. Also I filed down both F-631C brackets to match the contour of the fuselage.
Drilled the F-631C and F-631D cabin frame brackets to the fuselage. The was a small bit of interferance with the seat back stops so I had to take a small chunk out with a cutting wheel.
Spent the entire day working on the Cabin Frame Sub-Assembly. All match drilling completed, counter sunk and deburred. The forward section was also riveted together.
There were a number of tasks being held up by the cockpit paint so I decided to go ahead and get that done. I masked everything off and applied one coat. I let that dry (cure) 24 hours before applying the next coat.
I spent the majority of my time preping and painting interior cockpit panels and the brake pedals for final assembly and installation. I also drilled and installed the brake fluid resevoir and the Tee that mounts on the firewall.
Today I did a few miscellaneous things around the shop, clean up and organizing. Then I started a bit of painting on the cockpit panels and components. I also blind riveted the caps on the center section. I ran out of LP4-3's because I used some on stiffening the arm rests. I'll order more from Vans. I also began organizing to start rigging the brakes.
Match drilled the 782C to the angles on the floor. Riveted the 601TD to the firewall. I've noticed many of the builders adding some type of stiffeners to the ribs on the side walls of the cockpit. i thought that was a good idea. They seemed a big weak. I've heard they can be damaged when occupants pry themselves out of the cockpit.
Today I installed k1000-08 nutplates on the floor section of the F-782C after match drilling to the supports on the cockpit floor. I installed the nutplates on the F-601K firewall recess and fabricated the F7110-R and F7110-L stick boot rings. Believe it or not most of the time today went into the boot rings.
Today I spent time on small jobs around the shop. I did a bit of cleaning first. I edge deburred the cockpit cap strips and match drilled them. I edged deburred and dimpled the firewall recess plate. And I fabricated the F-601TD break plate and riveted it to the firewall.
I completed the blind rivets on the baggage area floor skins along with the k1000-08 nut plates and AN426AD3 rivets at the back of the baggage area. Next I drilled and trimmed the flap actuator bearing blocks and the flap actuator itself and temporary installed it. It will have to come back out for cockpit painting which is getting nearer to being necessary.
Today I removed the back skins in the baggage area to open up the cockpit for working along with the side baggage area access panels. I blind riveted the baggage area floor skins.
Today was a great day of building. I assembled the F-782C and associated components, primed and riveted them together. I had also been saving up other components for a priming session (such as seatbacks and elevator push rods) so there was a fair amount of time with the priming.
Okay, today was supposed to a highly productive day. I've taken off two days from a project to stretch the weekend into a 4 day builderama. After squashing a virus relaying through my mail server and taking care of a bit of client business I managed to rivet the co-pilot seat stop onto the fuse. Next I started fabricating the tunnel cover and then, yep, you guessed it. I broke my LAST bandsaw blade. Rather than wait 10 days for another one I called around and found an industrial supply company that makes them. I drove ACROSS town and had a couple of great 10 tpi blades made. I was able to finish the tunnel cover (rivets and all) but that was it for the day.
Today was a very productive day in the shop. I did a bit of assembly on the control sticks. Then I finished fabricating the rudder and brake pedal bracket (including the lightening holes). Next I completed the drilling positions on the pedal assembly to the fuselage. I only installed 3 positions but that should be enough. Lastly edged deburred then primed and riveted the elevator bell crank.
Today I did a bit of shop clean up and shortened one saw horse. This will lower the fuselage so I can lean over and work with it easier. I reworked the bottom hinges (again) on both seat backs and got it right this time. Next I edge primed both seat backs and riveted them together. It took longer than I thought to get all this done, pretty much the rest of the day.
Fabricated and match drilled the co-pilot seat back.
No Pics
1/10/2007
3
This evening's session was spent completing the "Pilot" seat back. All the angle is cut and drilled, seat back brace is completed with lightening holes and all the hinges are in place. I noticed something about the plans. The hinges are called out at 15 1/2 inches. If you cut them that way they are short enough to not allow proper edge distance on the ends for riveting. I had to recut them from the cowl hinge and reorder a piece of cowl hinge.
I finished constructing the brake and rudder pedals. It's important to note here I put all the correct hardware on but did not tighten anything or insert the cotter pins. Somehow I have a feeling I will end up taking it apart.