Progress update... final stages

Well, progress has been steady.

Magnetometer and compass calibrated.  Magnetometer had to go back to Dynon, and they just sent me a new one.  I had standard AN bolts fastening the magnetometer, which are now replaced with brass.

The header tank sensors I used are... well... garbage.  Not going to live with that, so the tank is out and new sensors ordered.  Tank removed.  Parts arrive today (2/11), hoping to get the new bungs welded in tomorrow.  Have to create a circuit for the display.  Actually looking forward to that.  

Aircraft is at the paint shop for touch ups and polishing.  I still have access, but its on the other side of the field... lots of trips back and forth for tools.

Had a fuel leak around the pump assemblies.  Fixed.

Another brake leak on the park brake valve.  Fixed.  Need to top up the reservoir.

Prop settings updated for UL520T.  Was set for UL520IS.

Started log books / maintenance schedule / out of phase tasks.  Draft of prop log / maintenance schedule, etc complete and reviewed by peers.  Minor changes recommended.

Things left to do:

1. Finish log books
2. Print W&B
3. Lower aft strut fairing fasteners
4. Set fine pitch stop on prop.
5. Aft belly inspection panel
6. Document all control surface deflections.

After that, its time to get flying again and get my training plan ironed out.

Nice photo shoot on Sunday.

Main gear toe

5 years ago when i drilled the gear legs, I used a method on the forum to align the gear legs.  It was not the correct method.  I knew it as soon as I put weight on the gear.

At the time, I did not see any point in trying to fix it as there was a lot of weight to put on (engine, wings, etc).

I've checked the gear toe a couple times and knew it was out (toe in).

After consulting the gurus, today was the day to figure out how many shims need to go in.

Measured the toe in a 3 point attitude.

Rolled the aircraft into the hangar, and left the tail sticking out the door.

String line from the tailwheel, plumb bob on centerline of fuselage at firewall.  Taped the string to the floor.  Yard sticks on the tires and centered.  Measured from yard stick to string line.

Results:

Shims ordered from Aircraft Spruce.

Sims installed!  Had a delay as the axle bolts were not long enough anymore, so had to order and wait... done now.

Lots and lots of progress on little things...

Progress is fast and furious.

Aileron bolts safety wired.  Boy, that was fun.  Had to make tabs for the outboard bolts to tie to.

Had another park brake valve leak.  5606 all down the belly (well, one long stream).  One fitting was not quite tight.  Tested extensively and no leak, and fluid level holding steady.

Compass swung and magnetometer received back from repair and calibrated.  Initially the magnetometer would not calibrate as I had used standard AN3 bolts to mount it.  Switched to brass, and all good now.

Full power run for 3 minutes.  Ran great.  Have downloaded engine logs and need to review.  Oil temps creaped up into the yellow.  Temp spread on intercooler was 26 degrees.  Prop spun up to 2680, but then came down to 2600.  Need to check prop settings.

Autopilot bridals for capstans installed.  Had to fine tune the forward elevator bracket, but got it.  Initial autopilot calibration complete.

Shims installed on main gear.  Looks good now.

All cotter pins, etc verified in aileron and flap systems.  All turnbuckles safetied.

Left wing servo tab pushrod fabricated and installed.  Perfect.

Aileron rigging complete and dead on.

Wing tips attached with screws and not clecos :-)

What remains...

• Logbooks and paperwork pre final inspection
• Paint touch up and polishing
• Header tank sensors... figure out a new plan.
• Fuel tank calibration.  I have a sticky sensor, or a bad wire in the left aux tank
• Exterior placards (door open, fuel tanks, etc).
• Install all inspection panels after final inspection

Getting closer...

Lots on the go.

Rigging of the control surfaces was 100% complete... then realized that the balls on the ends of the flap control cables had come out of their sockets.  Fixed.  Still need to check tension and safety those cables, but all of the rest are complete (ailerons, elevator, rudder).

Trim tabs set, calibrated on the EFIS and deflection measured.

Shims for main gear toe ordered and received... need longer bolts.  Should arrive Feb 3.

Magnetometer / compass swing:  My Dynon magnetometer was calibrated backwards - sent for recalibration.  Hopefully it will be back this week.

Cleaned fuel filters.

Fuel tank calibration partially done - right wing is complete.  May need to redo as sensors are sticky it seems.

Installing the autopilot bridles today.  Then that can be calibrated.

Placards started.

Fuel control system checks end to end for jam nuts, cotter pins, etc underway.

Wingtip Issue

For my fuel vents I used the combination of the JD air parts vents, and an andair (bleeding type) check valve.

So this means that the wingtip has a U shape cutout for the vent.

I put the port wingtip on after paint, and the small piece of fiberglass between the vent aft broke (I should have known better).  It's usually about a 1" strip between the counterweight slot and the wing.  The U shape cutout means its less.  Far less.

Cut that piece off and it is now permanently attached to the airframe.

Will add a picture one day when i remember to take one.

Aileron rigging

Finally got around to rigging the ailerons.  This was complicated somewhat in that I lost one of the pushrods during the move (I think...).

But everything worked out really good, except the aileron counterweights need a bend to achieve down sufficient down aileron clearance.  Easy job.

Getting the jam nuts tightened is a challenge on the wing side.  So little room and I have big hands.  Trying to make a tool to help this this.  My friend found some wrenches and he got one side tightened up.

Had to bend the counterweights.  Done, no contact with the wingtips.

Achieved 22.5 degrees up, and 17.5 degrees down.

Fuel Flow Test

Finally after a whole bunch of rework the header tank vents are done and fuel flow testing complete.

Achieved 18 degree pitch angle (that sure was fun).

Fuel flow test results.

I performed both the pump and gravity tests, as the fuel is gravity fed to the pumps.