emkrueger830
Fuel Gauge Calibration
Calibrated fuel gauge by pumping fuel into tank from marked 6 gallon homebrewer’s bucket. Opted to calibrate fuel gauge in “ground stance” position (~8° nose up) and with ethanol free 91 octane mogas. Set points was recorded every 2 gallons per Dynon setup instructions. Due to probe length and aircraft attitude, probe reads full above…
Aileron Rigging
Created aileron neutral alignment tool with two rulers similar to the one used for flap rigging. Set neutral position for RH aileron and centered stick assembly using digital level. Adjusted aileron pushrod length via rod ends then secured RH aileron to control stick. Repeated process for LH aileron. Verified freedom of movement and range of…
First Engine Run Prep
Began preparing engine for first run by draining preservation oil from engine and replacing 3.7 quarts of Shell 15W-50 oil. Replaced oil filter with NAPA 1394 Gold oil filter. Removed and replaced all 12 NGK D9EA spark plugs and set gap at 0.023″. Torqued rocker cover bolts to spec. Installed Sonex exhaust pipes onto engine…
Stick Grip Wiring
Installed control stick ground wire and autopilot ground wire in GB24 ground block. Ran and routed PTT wires from mic jacks to stick grip harness and began populating fuselage side of connector. Attached aux fuse block power and ground wires to fuse block. Ran smoke system control ground to stick and left extra length on…
Control Frame Installation
Fabricated auto pilot push rod bracket from spare 2″ aluminum angle and bolted it to bottom LH side of control frame with AN3 hardware. Upon initial fit of the frame, discovered that aileron stops were contacting ends of spar tunnel bolts so trimmed approximately 3/8″ off each end of aileron stop. Stops still contact frame…
Fuel Leak Testing and Vent Installation
Added fuel to tank in order to test firewall forward side of fuel system. Upon opening fuel shutoff valve, discovered that hardline to system drain was leaking from both AN fittings. Upon removing the line, discovered that the flare fittings were not made properly. Remade hard line and installed new fittings. Leak checked firewall forward…
Stick Grip Installation
Finished securing wiring behind instrument panel and underneath sub-panel shelf. Drilled wire hole in bottom of both control sticks for stick grip wiring. Aligned stick grips and drilled pilot hole in grip and control stick. Updrilled holes and tapped stick for 8-32 set screw. Installed stick grip foam onto each control stick and fished wires…
Initial Prop Installation
Began initial prop installation by enlarging holes in Jabiru prop bushings from 1/4″ to 3/8″ using drill press. Verified holes in prop did not need any reaming but needed to ream holes in spinner slightly to allow for smooth bolt installation. Bolted prop and spinner to prop flange using AN6 hardware and AN363 lock nuts.…
Stick Grip Modification
Opted to modify internal wiring inside the Ray Allen G403 stick grips in order to isolate PTT ground from other function ground. Removed screws in stick grip in order to remove circuit board from plastic housing. The default wiring is set up so that all functions share a common ground and the momentary/latched toggle switch…
Elevator and Rudder Rigging
Connected rudder cables to rudder horn per plans and installed rudder cable fairings on fuselage. Installed hardware for elevator push rod and lubricated bushing with LPS-1. Riveted SNB-F23-09 pushrod assembly to fuselage and verified freedom of movement in elevator control system. Hours Worked: 1.05
Tailwheel Installation – Part 3
Epoxied tail spring rod into fuselage using 3M DP8407 metal epoxy to strengthen connection since rod had a little bit of play in tail spring mount bracket. Installed tail spring hardware. Upsized steering linkage rod holes in tail wheel assembly and rudder horn then installed Anson Engineering steering rod. Used torque seal on hardware. Hours…
Wiring Cleanup – Part 1
Installed aux power fuse block and SkyView splitter on underside of cross tie box with rivnuts. Worked on organizing and securing wiring under panel with zip ties and adhesive pads. Cut off unused EMS wires and secured into bundle in case of future upgrades. In spots where wire crosses over or under throttle controls, placed…
