airworthy

Total time: 3030 hours.
Misc: 20.0

Got our special airworthiness certificate! This marks the official end of the build. There is still work to do, but since in the eyes of the state, I have an airplane I can legally fly, I will no longer be tracking my time.

Now just have to sort out a few squawks and we’re ready to fly.

  • Prop Governor issue (was bad cal in tach)
  • replace overhead air servo
  • fuel flow test
  • arm and test ELT
  • clean fouled plugs
  • plug unused nutplate in firewall
  • verify GPS getting to ELT
  • fix fuel leak in tunnel
  • FAA inspection
  • Recheck flap/aileron rigging
  • Adjust oil line to avoid rubbing on air box
  • add some “cushion” to the forward stops in the engine controls.

… Update … Service Bulletin 632 was just released by Lycoming. Looks like our first flight will be delayed for a little bit longer.

 

 

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Engine start and other stuff

Total time: 3010
Firewall Forward: 95.6
Misc: 65.5

Too much stuff to mention in detail. And not too many pictures. Most notable, as of this date (6/30/2017) the engine has been run for 0.4 hours. No issues.

Here’s a general list of things done.

  • trim on window interiors
  • configuring skyview
  • EarthX battery connect and battery fault testing
  • Interior scat vent tubes
  • Interior front panels
  • Interior center console
  • Wing tip wiring
  • Pitot install
  • Fix short circuit in left nav light (was just a bit of aluminum shaving that got caught in a connector.
  • Secure wiring in wing root
  • VOR antenna in left wing tip
  • EFIS setup
  • Flap position calibration.
  • Reposition engine controls (big job here to fix interference with original engine control layout)
  • Had an EAA inspection.
  • Fixed binding in right aileron
  • Painted elevator counerweights
  • Calibrated trim positions
  • Wing root fairings
  • Calibrate fuel tanks
  • Had avionics shop inspect Pitot/static system and VOR and got an IFR instrument checkout

Grips and Misc

Total: 2517.1
Misc stuff: 8.5

Put connector on the sticks that fit through the sticks so they can be removed easily. Also had what I thought was an issue with the PMA450a (audio panel) fit. It have some give vertically when in the tray. I thought I had done something wrong in the install but in the end this is normal. I’ll put some rubber between it and the GTN650 which will be installed above it.

Also installed the “shore-power” connector in the rear panel behind the baggage compartment. This will allow the battery to be recharged and for the charger to be connected when on the ground so as not to drain the battery when the engine is not running.

Not may pics of this stuff. Might add more later.

Panel labels

Total: 2227.1 hours
Total Panel and wiring: 144.0 hours
Total Misc: 5.7 hours
Panel since last time: 30.0 hours
Misc: 4.5 hours

Painted and put labels on the instrument panel. This process was more involved than anticipated. But in the end, it looks really good. I used a system called DecalProFx to turn the labels, once designed, into decals. Then when I was happy I clearcoated the whole panel. To design the labels, believe it or not, I used PowerPoint.  The decalPro process is a little involved and took a few hours to get “good” at it. The hardest part turned out being positioning the decals on the panel but I found a process that worked fairly well.

  1. Design the decal with a nice thick boarder (the boarder is required when making the decal anyway)
  2. Print it on regular paper and cut it out
  3. position it on the panel and hold it in place on one side with scotch tape.
  4. carefully cut out the interior with a small pair of scissors and tape down the rest of the boarder.
  5. Make the decal and use the boarders as a guide for positioning. Also on the decal put in a circle for holes in the panel where applicable. Mask the holes when applying the glue to keep them from sticking. The holes make a great guide.

Note that I also learned to mask off everything on the “mylar carrier” but the graphic itself from the glue application. This makes positioning a lot easier since nothing will stick except the graphic itself.

Because I wanted to put a graphic on the pilot side air vent indicating the location of the parking brake, I also created the bracket necessary to hold the brake pull-cable and I went ahead and installed the whole thing. And I also put a graphic on the head of the pull-cable.

Lot’s of time but worth it, I think. The panel labels look very good in my opinion. The labels themselves look professional. The positioning of the labels could be more precise in a few places but I don’t think the positional flaws will be noticeable once the panel is all populated with switches and screens and all.  I would recommend the decalPro kit to anyone doing the same thing. Just note that you’ll need a laser printer and a laminator. And if someone could invent some way to hold the decal for positioning that would make placement much easier.

One special thing we decided to do because we had a lot of space on the right side of the panel was to put on a Bible verse. Actually after a family discussion where we all discussed what verse to use, we decided on two. Given the perspective of the creation from an airplane we decided to use Romans 1:20 which says, “For the invisible things of him from the creation of the world are clearly seen, being understood by the things that are made, even his eternal power and Godhead; so that they are without excuse:” Under it we have 1 John 5:20 which says: “And we know that the Son of God is come, and hath given us an understanding, that we may know him that is true, and we are in him that is true, even in his Son Jesus Christ. This is the true God, and eternal life.”

I also spent a little of this time installing a doubler for a GPS antenna in the back between the comm 1 antenna and the ELT antenna. This marks a change to the original plan which has this antenna on the cabin top. After realizing the amount of work for this antenna which requires a ground-plane and if installed on a non-metallic surface, a grounded braid around the RG400 cable, I decided to relocate to a metallic airframe location. This solves both the ground-plane problem and eliminates the need for the special braid. And it meets the spec of more than 2′ away from any other antenna. I don;t anticipate a problem. There was already a spare coax going front to back and in case it doesn’t work out because of proximity to the other antennae, I’m leaving the cable which runs to the cabin top in place.

 

Seats and pitch trim

Total: 1995.3
Seats and pitch trim: 4.9

Getting engine and prop ordered. Doing some miscellaneous tasks. Got the seat rails installed and though I forgot to get a picture, the front seats slide in and out without issue. I cut off about 3/8″ from the front plastic seat rail guides from the seats themselves and this allows me to remove and install the seats without removing the flap tube access panel.

Also put in the pitch trim mechanism.