Powerplant
AeroInjector Tuning – Part 1
Began process of tuning the AeroInjector. Immediately had issues getting engine started and struggled to keep it idling normally. The partial firing seems to indicate a too-rich condition with the #3 needle. Upon trying to adjust the needle, there were issues trying to turn the needle clockwise to lean the mixture. Decided to remove cowl…
Lower Cowl Rivets
Riveted cowl side vents, exhaust tunnels, and lower cowl hinge halves to lower cowl. Hours Worked: 1.10
Temporary Prop Installation
Temporarily reinstalled prop and spinner for engine test runs. Installed upper cowl and verified clearance with prop. Hours Worked: 0.97
Cowl Nutplates and Oil Door Fabrication
Updrilled cowl shelf, lower cowl, and upper cowl, and drilled and riveted nut plates onto cowl shelf and lower cowl. Temporarily installed upper cowl onto aircraft with screws to verify alignment and fitment; checks good. Located oil dipstick with flashlight and marked location of oil door on upper cowl. Removed upper cowl and cut rough…
Engine Baffle Installation – Part 3
Removed AeroInjector needle carrier and replaced stock #2 needle with recommended #3 needle. Reinstalled needle carrier and set needle setting per manual by marking start of taper and aligning it with top of throttle slide. Reinstalled set screw and dust cap. Safety wired AeroInjector to engine via intake pipes. Decided to modify baffles to make…
Firewall Sealant and Engine Preheat Wiring
Removed wire grommet covers from firewall for fear of wire chaffing and riveted open holes closed. Riveted upper cowl shelf to windshield skirt. Applied 3M Fire Barrier Sealant CP 25WB+ to gaps in firewall around motor mounts and on seam between windshield skirt and upper firewall. Also applied sealant to wire bundles, brake lines, and…
Fuel Line Insulation
Added fire sleeve insulation to fuel lines forward of firewall. Used smaller size (5/8″) for hard lines and flex hose and separate larger size (1.5″) for fuel filter. Secured sleeves with zip ties. Fuel system complete! Hours Worked: 0.64
Cowl Fiberglass Work – Part 9
Rough sanded micro on upper cowl then final sanded; upper cowl should be finished with most micro work. Added micro to two low spots on lower cowl and let micro set. Fine sanded the two spots on the lower cowl with 120 grit; finally micro work should be finished. Laid out side exhaust vents onto…
Cowl Fiberglass Work – Part 8
Removed upper and lower cowls from fuselage and removed packing tape from fuselage. Rough sanded new micro; most spots very close to being done with fiberglass but a couple of spots needed more filler. Leaving cowls off of aircraft, mixed another batch of stiff micro and filled the couple of low spots in both the…
Fuel Vent Rework
Removed existing steel fuel vent to rework due to poor fitment. Used 1/4″ OD aluminum tubing instead as it is easier to work and bend. Essentially followed same path as previous vent with better routing. Added Adel clamp (temporarily) along fuselage floor to help secure hard vent line. Will reinstall once floor goes on permanently.…
Cowl Fiberglass Work – Part 7
Rough sanded aft edge of upper cowl then pinned into place on fuselage. Further sanded cowl on fuselage to get spacing correct. Removed upper cowl and sanded transition line with 120 grit. Removed lower cowl to trim prop hub area and prep a few small spots for epoxy. Reinstalled cowls and secured into place. Prepped…
Cowl Fiberglass Work – Part 6
Removed lower cowl from fuselage and removed hinges and clecoes. Rough sanded new work with 60 then 120 grit; transition mostly okay with just a few low spots to fill in. Reinstalled lower and upper cowl onto aircraft. Marked prop hub trim line with 3D printed guide to maintain 0.125″ clearance between hub and cowl.…
