AN960-416
Autopilot Installation – Part 2
Attached D-sub connector to roll servo wires then installed servo onto fuselage floor. Attached aileron servo push rod and verified servo arm did not contact over center bracket. Roughed in location of pitch servo and marked bracket location on floor. Removed pitch servo and installed Dynon-provided stiffener on floor. Installed servo onto bracket, installed over-center…
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…
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…
Brake System Assembly – Part 3
Manufactured master cylinder mount components out of aluminum sheet and angle stock. Because the B-Model plans do not have provisions for a center mounted brake lever, used “sport trainer” plan set from the legacy plans for part dimensions. Also substituted two 0.125″ spacer plates on each side of the mounts rather than one 0.25″ piece…
Flap Rigging
Began rigging flaps for final installation by trimming flap pushrod length from 3″ to 2″ to allow more adjustment of rod ends. Removed flap motor from drive tube for easier access and started by testing position of LH flap. Adjusted lower pushrod end to achieve full-up flap neutral position of 2 59/64″ measured from the…
Wing Installation – Part 1
With help, mounted left and right wing assemblies onto fuselage. Attempted to add weatherstripping on inside edges of wings but there wasn’t enough clearance; will likely seal gaps with tape later on. Before sliding wings fully together, connected wing root connectors and pitot/AOA connections. Opted to use drilled hardware and cotter pins for wing bolt…
Throttle Bell Crank – Part 2
Installed throttle cable in center panel area. Located throttle and mixture cable pass-through locations on firewall and prepared holes for cable bulkheads. Installed both cable safes. Located throttle bellcrank assembly based on throttle cable pass through then transferred mounting holes onto firewall. Cleaned up bellcrank assembly then riveted pieces together and to firewall. Tested cable…
Engine Hardware Replacement
Replaced temporary engine mount hardware (too long) with properly sized AN4-46A bolts and AN363 nuts.
Mounting of FWF Electrics
Began mounting FWF components on firewall by laying everything out in a logical order then marking and drilling mount holes. Installed nutplates for all fixtures to enable easy replacement in the future. Temporarily mounted starter solenoid and voltage regulator for now pending proper bolts and ring terminals for ground wires. Hours Worked: 2.87
Rudder Control System – Part 2
Heated up C01-03 rudder spring stock with propane torch and bent springs to specs in plans. Previously tried to bend springs without heat and spring steel broke rather than bent. After installing springs into fuselage, discovered that plan dimensions were a little long and resulted in rudder pedals not returning to neutral. Shortened springs by…
Elevator Control System – Part 1
Temporarily installed control stick assembly. Pressed SF-812-3 bushings into stick to idler bar and control frame then installed idler hardware permanently and stick hardware temporarily. Verified freedom of movement and clearances with idler bar. Pressed bushing into elevator push rod ends, clecoed forward pushrod support to cross ties, and checked clearance of elevator push rod.…
Tail Installation – Part 3
Mocked up ELT location on rear shear web and marked vertical stabilizer on where skin needs to be trimmed. Removed vertical stabilizer and marked out mounting hole location on shear web. Trimmed vertical stabilizer skin and riveted ELT mount and clamps to fuselage. Painted elevator horn with spray paint. Reattached vertical stabilizer with AN3 and…
