Tuesday, July 17, 2018

Making (slow) progress on finish kit

Shortly after receiving the finish kit, I started the installation of the rear window.  Followed instructions very precisely/carefully and when almost finished with drilling, I noticed a crack on the leading edge:  this crack extended about 2 1/2 inches.  So... I re-ordered the window.   Got this installed over this past weekend, no issues.  Also have completed the canopy open/close mechanism and have started prepping parts for main canopy including initial riveting of the canopy hinge assemblies.   Lots of parts cut out from punched parts and also prepped to varying degrees.

Heading to Oshkosh soon so won't be getting back to work for the next 10 days or so.

Saturday, June 30, 2018

Finish Kit - Finally

Finally received finish kit.   Unpacked and inventoried, and today started on fitting rear window.

Friday, June 1, 2018

June 1st 2018 Update - waiting for the finishing kit

Since last post I've mostly been doing a few odds and ends - finished up the fuse kit by installing the control sticks and wiring harnesses for these: I added extensions which I connected using dsub pins with shrink wrap.  This made it easier to get the wires to the sticks.  Worst part of Van's design I've found so far: it is IMPOSSIBLE to route the stick harnesses with molex connectors in place through the structure from tunnel to sticks as Van's prescribes.  Even getting the bare wires through there is very hard.  It's an insanely tight space to work it and the angle is very hard to make.   (Rant over).

Finish kit should be here in a couple of weeks, excited to get that going.

Friday, May 4, 2018

Finishing up roll over structure

Since last post, completed all the drilling, countersinking, riveting, painting, and installation of the roll bar assembly.  Still need to rivet the aft brace to the skin and baggage bulkhead.  After this will install the skin stiffener next to roll bar and that will wrap up section 37.

Wednesday, May 2, 2018

A forest of clecos - and a very sore hand

Since last post, I fitted the co-pilot stick to its base and checked travel limits of the stick (as well as verifying that stick bases are contacting both stops: I had previously checked this and filed one of the stops so this was just a verification).   I'm good with stick travel - about 14.5 degrees down and 25 degrees up so no adjustments needed at stick.  It will be a while before I install the aft-most control rod because I need to move things around in the shop to get the HS / elevators mounted in order to check travel there.

Also prepped / primed the rollover structure parts, and starting by riveting the two "halves" of the forward and aft sections of the roll bar.  Next I clecoed the structure together and final-drilled from #40 to #30.   LOTS of cleco action here - my right hand is very sore!

I'll deburr everything well and start riveting this in the next day or two.

Sunday, April 29, 2018

April 29 Update - odds and ends including flap position sensor.

I installed the flap position sensor today.  I replaced the micro-molex connectors with Deutsch DTM connectors.   Also used DTM connectors for the power wires.  Nice

I ordered a bunch of these and will be using them where it makes sense. 

I've started deburring parts for the rollover structure and painting parts that will be part of that section.

Also fitting control sticks (I ordered Tosten sticks from Vans) to the bases, preparing to install sticks and stick connecting rod.

Monday, April 23, 2018

April 23 Update - close to wrapping up fuselage

Since last post I've completed several tasks including:

  • Installed baggage side covers
  • Touched up paint in baggage area
  • Installed flap actuation system
  • Installed fuselage wiring harnesses
  • Installed elevator pushrods
  • Installed pitch and yaw servos in tailcone (still need to attach to the rudder cables - will wait until I have empennage mounted 

I still need to install control stick bases, stick link pushrod, aft-most elevator pushrod and then test range of elevator movement.

The only incomplete section on the fuselage is now the rollover structure - hopefully the completion of this will coincide with arrival of finishing kit.

Making (slow) progress on finish kit

Shortly after receiving the finish kit, I started the installation of the rear window.  Followed instructions very precisely/carefully and ...