emkrueger830
Exhaust Tunnels – Part 1
Bent exhaust tunnels and outlet lips from firewall forward kit blanks. Made flange tool out of scrap phenolic. Bent tunnel sides using bending brake then bent mounting flanges using homemade flange tool. Aligned exhaust tunnels onto newly cut cowl openings and pilot drilled and clecoed exhaust tunnels to lower cowl. Tried to install lower cowl…
Cowl Fiberglass Work – Part 4
Removed upper cowl from lower cowl again and began sanding upper cowl. Started with 60 grit and moved up to 240 grit sandpaper to better blend transition area. Finished sanding with upper cowl mocked up onto lower cowl to better blend transition. After sanding most of the new work with 240 grit, discovered a few…
Cowl Fiberglass Work – Part 3
After allowing epoxy to cure, used 60 grit sandpaper and hand sanding block to rough shape cowl curvature and knock down spatter and high spots. Tried to focus on transition areas between existing cowl and new work to make transition smoother. Initial sanding identified multiple valleys and pin holes that will need another coat of…
Gear Leg Fairings – Part 2
Placed 1.125″ Adel clamps around LH landing gear leg and marked approximate mounting hole position on gear leg fairing. Removed fairing and drilled mounting hole in fairing. Temporarily bolted fairing to landing gear leg to mark second mount hole location with Adel clamp. Removed fairing again to drill second mount hole and deburr holes. Installed…
Cowl Fiberglass Work – Part 2
After leaving the fiberglass to cure for a couple days, marked rough cut line and gently pried the top cowling off of the bottom cowling without incident. Rough sanded upper cowl using 60 grit sand paper to level bottom edge and start to feather transition area. Temporarily installed top cowl back onto airplane to check…
Cowl Fiberglass Work – Part 1
Prepped upper cowl for fiberglass work by cleaning areas with acetone and adding more packing tape to lower cowl. Cut (3) 32″ strips of fiberglass for each side of the cowl at 1.25, 1.50, and 1.75 inches wide. Mixed small batches of West system epoxy (105 resin and 205 hardener) and saturated bottom strip before…
Pitot Installation – Part 2
Did some rough trimming of the RH side fuselage side panel to verify routing path of pitot/aoa tubes. Disconnected RH rudder cable to ensure all bundles were behind it then reconnected cable to rudder pedal. Drilled 1/2″ holes through fuselage vertical channel and installed rubber grommets. Routed lines though grommets then up RH side of…
Pitot Installation – Part 1
Leveled fuselage then temporarily installed pitot mount into RH wing to calculate spacer size needed to level pitot tube. Made 2 0.125″ spacers (0.25″ total) out of 0.125″ aluminum sheet to place under back side of pitot tube mount. Installed mount into RH wing, checked levelness, then installed screws. Installed pitot mast into mount and…
ELT Installation
Located and drilled hole for ELT antenna on aft portion of turtle deck. Secured antenna to fuselage then routed and connected coax cable from antenna to ELT. Cut hole in RH #1 former for RCPI and drilled mounting holes. Installed vertical faceplate and A544 alkaline battery into RCPI (battery expires 06/19/2031) then mounted RCPI onto…
Cowl Fitment – Part 7
Continued to sand lower edge of upper cowling in preparation of lengthening the lower edge using hand and orbital sander with 60 grit. Finished rough sanding with 120 grit discs; should now be ready for fiberglass work. Cleaned upper edge of lower cowl with paint prep solution and applied packing tape to overlap area. Covered…
Cowl Fitment – Part 6
Began prepping upper cowl for fiberglass work by removing prop and spinner from engine then reinstalling lower cowl and cowl alignment spacer. Placed upper cowl into approximate position and secured to spacer. Traced 1.5″ line along upper cowl to mark limits of new fiberglass. Removed upper cowl and began to feather lower edge in preparation…
Card A – Fuel Flow Test
Configuration: Cowl removed; inspection covers for all fuel pumps and valves removed. Procedures: Results: Overall fuel flow rate from 19.25 gallons to 0.00 gallons was 22.95 GPH Gallons Time (Sec) Time (Total) Rate (GPH) 19.25 0.00 0.00 0 18 126.81 126.81 28.39 17 134.05 260.86 26.86 16 149.89 410.75 24.02 15 150.21 560.96 23.97 14…
