All the little details...

So many things to finish.  

Final inspection schedule for somewhere between March 3 and 5.

I havent posted much because I have been so busy...

Log books are done.  Engine, Prop, Airframe and Journey logs.  POH is written.  Checklists are written. Maintenance manual is written.

Fuel flow test report is done and written.

TC's application for special cert of airworthiness.  Done.  All 3 copies.

Header tank has been removed, new bungs added, refinished, and reinstalled.

New level sensors for header tank obtained and installed.  New monitor board, indicators, and software complete.

Interior placards done.  Exterior placards waiting on polishing to be finished.

Paint touch ups done.

Tanks calibrated.

Fuel system leak found and dealt with.

Park brake valve leak found and dealt with.

Dealing with slightly sticky fuel tank sensors in main and auxes.  Checked against SB, does not apply.  Removed one sensor and checked.

Complete inspection on all control systems complete.

Deflection of all control surfaces verified.

Electrical system diagrams complete and printed.

All required paperwork done.

Went through checklist multiple times.

All exterior placards installed.

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.

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

The endless list of tasks to make a project an airplane...

Steady progress.

5 years ago I build a crossover cable guide.  I remember I wanted to make another one, had the material, and now I need to get it finished.  So today was make a new one and get it installed.  I want to get all the rigging DONE.  Found half of the old one...

I had a minor issue in the process.  The sheathed cable for the tailwheel lock runs right through there, and didnt want it rubbing on the control cables.  Easy fix... adel clamp on the crossover to cage mount (not shown in the pic).

Passenger door hung.

My wife started cleaning... so much dust, etc.  Very grateful for the help.

Started removing the interior.  Need to add the 2nd pulley for the roll servo.  That is tomorrow's job with the interior out.

Need to rebuild the park brake valve (which leaks).  Done.  Sent for testing... no more leaking.

Need to add the window to door silpruf to the rear door.

The lower hinge on the baggage door would not fit in the cutout.  My hinge was lost at the paint shop, so the owner pulled the hinge off his damaged Sportsman... and it wouldnt fit.  Slight trimming, and now it does.  Needs to get repainted.

Fresh hardware (of correct size) in the pulley clusters.  Added 2nd pulley to the aileron forward pulleys for the autopilot servo.  Still need to cotter pin them.

Elevator counterweights.

Fuel flow test.  Did not go as planned.  Put 5 gallons in each main.  Header tank would not fill (sensors did not indicate it reached 1/3rd).  Suspect lack of venting.  After a lot of troubleshooting, closed the fuel selector and blew air into the header from the firewall to free up the check valves on the vent line.  That worked, but exposed a larger problem of stuck check valves.  Working on solution.

Put the aircraft on the big tires, on ramps / scales, and remove tailwheel to get the nose high.

Achieved 14.5 degrees, which is not enough.  But that is not the main issue.  Blocked vent line is the issue.

Weight and balance

Park brake valve.... leaked.  Removed, rebuilt, tested and reinstalled.  No leaks!  Installed... need to bleed brakes and add fluid... again.

Cowlings!  Anti chaff tape added to joggles.  Fine tuning the fasteners (Skybolt) for optimal fit.  Will be a couple iterations of on and off to get everything right.  But it looks GREAT.

Walk down memory lane... remembering what it used to look like 2.5 years ago.

Amazing what paint can do... but even paint wont fix something that's ugly to begin with.  Taking the time to make the cowl look right was so worth it.

Passed pitot static test, but cannot get the tailbeaconx into test mode.  Wifi will not connect... well, wifi not even seen.  AFS5600 is setting the tbx to standby, which should enable the wifi.

Fitting the skybolt fasteners on the cowl.  On off on off, adjust, etc.  Almost done.

Park brake done and works.  Need to bleed brakes.

Pushrod for anti servo tab.  Drying in place, needs correct fasteners once pull test complete.

TailbeaconX being sent in for service.  Cannot get it into configuration mode to test for pitot static.

406 ELT:  Beacon registry erroring out on the HEX ID programmed by Aircraft Spruce.  Beacon registry admin says it was reused... previous aircraft with that ID has been exported and ELT reprogrammed, so form filled out to fix.  That should do the trick.  Done and done.

Updated wing shot... 3 view.  Could not help myself.

So many little things to finish.

Reinstalled the recognition light on the belly.  No workie.  The pins are not lining up on the connector.  Bizzare... No changes were made.  I removed the pins from the connector and attached manually.  Still no work.

Engine mount rubbers have compressed.  I went to tighten the bolts and they moved.  Need to investigate.

All bolts tigthened and imagine that, the cowl lines up better.  I think that is a good thing.  I still think the front is sagging a bit - but the spinner lines up.  Thinking that problem is elsewhere.

Went to reinstall the belly strobe / recognition light.  This should have been a 5 minute job.  Bolts go in, no problem.  Hook up the connector - nothing.  No stroby stroby.  Check the pins... all OK.  Remove the pins and test with a 12V power supply, strobe works fine.  Check the airplane side of the wiring... nothing.  Cut everything apart and check the bare wires.  Nothing.  Take out the PFD and check the connector for 'aircraft rear'. All good.  Was about to take everything apart to check the wire connectivity and think ground... check the ground.  No ground... On the ACM there are very few grounds... and I did not hook that ring connector up to the chassis ground.  FIXED!  Had to rebuild the connector and pins, etc.... but it works and its BRIGHT.  Thank you AVEO!

Waiting for a parts shipment from Aircraft Spruce... that has the engine oil heater, which I will need operating this time of year.  Will be here tomorrow.

Park Brake

I've always wanted a park brake.  The Emeraude doesn't have one, and I think it would be really nice to have.

On my ongoing quest to keep everything as far forward as possible... I have put the park brake under the centre tunnel, just aft of the rudder pedals.  I have been advised NOT to put it here, as it is a pain to get to (yes it is).  Usually this assembly is placed under one of the front seats.  I have a feeling I will be moving it one day...

McFarlane makes really nice locking controls, that can be custom engraved...

The park brake valve is from Matco.  Seems to be the standard valve that everyone uses in Glasair land.

When I was installing it, I pulled the cable out too far, and heard this tiny metallic 'bounce, bounce, bounce'... luckily I found it, a tiny ball bearing.  Without it, the lock does not work.  Luckily I am not the first one to do this, and McFarlane has a procedure to reinstall it on their website.  

Top down and side views.

This one is done...