Engine

Engine Dehumidifier /Dryer  ( 7 hrs )

Built Engine Dryer using recommendations per Bill Lane (local builder of RV 7) and several example posts in VAF.  This will minimize risk of corrosion inside engine if not run weekly (moisture accumulates from combustion).  Will connect the dry air output at Dipstick, with return air captured via Breather.   Uses aquarium pump (must be in air tight container itself with only air from Breather connected), to move air through about 2 quarts of desiccant.  I'll use white desiccant (lower cost) followed by small container of blue desiccant (color changes when saturated).  Small engine fuel filter insures clean air returned to dipstick.  I've also been working on 2 Wing Jacks, using 3 Ton hyd rams from Harbor Freight (also per examples in VAF)...pics soon.

Tool box services as container.  Original plug Lycoming ships
 engine with used to insert dry air into engine. Return air from
 Breather.  (small red caps keep clean until using)

Aquarium air pump is in air tight container so only return air from
engine is cycled.  Desiccant container also must be air tight.  Blue
 desiccant in "inline desiccant" vessel to provide indicator when
primary "white" desiccant is saturated.  Small filter just
prior to exit to engine insure "clean" air.

Lots of latex tubing (vinyl will get stiff in colder weather).  Pump
 has 2 outlets, so combined via T fitting.   Created distribution
 box for air inside desiccant container using small
plastic box (or drill alum tube, etc)

Firewall Forward Kit

Exhaust Installation ( 2 hrs )

Continued Exhaust install per 48-02.  Added Hangar Links.  Adjusted angle of Hangar Angles to 123.5 deg using provided template.   Step 4 required disconnection of Nose Gear Link (ref Sect 40A-06). to install Tailpipe.  Fortunately, another builder documented this - Vans doesn't describe.  I tried w/o doing 1st, but seemed impossible otherwise.  Used engine hoist to release load on nose wheel.  Tailpipe installed and gear re-assembled.  Ready to add remaining exhaust tubes, but trying to do as much as practical prior to opening engine to air/moisture - since 1st start is likely few weeks away.

removed bolt holding nose gear link...with engine hoist
lifting load entirely off nose wheel

tah dah ! 
Tailpipe installed on hangars in central tunnel

re-attached support link to Nose Gear. 
Ready to add exhaust tubes forward

Firewall Forward Kit

Exhaust ( 3 hrs )

Received engraved Data Plate, Fuel Caps, and N number decal from Net Engravers.  Very pleased with results.  Re-installed 4" SCAT (air duct) to oil cooler.    Installed RH Vent cover per Sect 48-04, Step 1.  Completed Steps 1-4 at Sect 48-03, various hangars, tubes, & brackets.  Belt sanded raised edges at relief notches ( per Step 2, 48-04) on eight Heat Muff Ends.

Data Plate engraved,  Fuel Caps engraved, and N number
decal.  Small decals "free" for trial application, etc

Looks great !

Re-installed 4" SCAT after adding
TCW butterfly valve

various pieces prepped for installing Exhaust.

Transition Training

Transition Training with Mike Seager

Flew commercial to Portland, Oregon, then drove an hour northwest to Vernonia, Oregon.  Stayed at Carpenter Guest House B&B (carpentersguesthouse@gmail.com, 541 961 8601).   Met Mike Seager for my Transition Training (email rv6cfi@hotmail.com, 503 709 4075) at Vernonia Muni Airport (05S).  The week prior, Mike notified me Vans RV-14A would NOT be available (until June 3! ) due to scheduled updates, etc.  Discovered the RV-14 (taildragger) instead had been reserved back Feb 1.  I quickly received confirmation from Falcon Insurance that the underwriter Global was OK w/ using Vans RV-7A for my training.  Mike assured me the 7A flies nearly identical to RV-14A.   We flew Thurs & Fri, April 11-12 in morning and early afternoon.  Rains and low ceilings made flying over  mountains exciting enroute to Scappoose (KSPA) and back.  Lots of pattern work at KSPA.  I gradually got used to CS prop and high sink rates on approach (vs C172).  Abundance of power is understatement -- takeoffs were more like launches!  Mike's a great instructor ( 22,500 hrs mostly in RVs).   On Saturday, I had time prior to flight home to visit Evergreen Aviation Museum ( about 1.2 hrs south of Portland)...the Spruce Goose is amazing!

Mike Seager getting RV-7A ready.

Rare partial blue sky...it's damp in Spring in Oregon!

Spruce Goose.  Over 300' wingspan. 
You could stand up inside wings.  8 engines each 3000 hp.

One of many planes of all eras on display.

Finish Kit

Crow Safety Harnesses ( 2 hrs )

Installed Crow 5 point Safety Harnesses ( Part # R40004P ) purchased earlier via Abby at Flightline Interiors.  I received 6 replacement "Tangs" with 5/16" holes at mounting points after contacting Fred Crow - to match Vans instructions and dwgs using their provided bushings.   Probably could have used the original w/ 1/4" holes, but prefer matching Vans plans per Sect 42-06.  They were easy to replace.  Waiting to install Crotch Straps (which actually did have 5/16" holes to match AN5 bolts) until I'm ready to install Seat Ramp Covers - per Sect 42-02, Fig 1 & 2.   Starting to install Exhaust system.   Per 48-04, drilled out LP-4 rivets on right side to install Right Vent Assembly (ie cover) per Fig 1.   Engine mount tubes makes this difficult (Vans should insruct this step PRIOR to adding engine mount, etc !).   Used 90 deg angle drill for one, but other needed 11" extension also.  Gonna be real tight to blind rivet soon...but seems do-able.

Crow harnesses mostly installed.

Poor access required 90deg AND 11" extension
 to drill out rivet.  Seems Vans should have
 you do this well prior to adding engine mount
and engine! (vs during exhaust install)

Finish Kit

Brake Fluid added ( 1 hr )

Finally added 782 (synthetic) brake fluid.  Followed excellent article by Jon Croke (of Homebuilt Help) in Nov 2018 Kitplanes mag "Bleed like a Pro".  ( also referenced several posting to VAF demonstrating same technique).  Used his recommended simple, low cost high pressure oiling can (under $10).  Attached nylon tubing to nipple on brake caliper, loosened 1/2 turn and pumped.  Takes a lot of pumps.  Interesting to check progress in translucent brake lines as fluid pushes air out making circuit all the way to reservoir on firewall.  Used a "dipstick" to insure not overflowing.  RH first, then LH brake....then "VOILA"...done.   Brakes seem firm, and NO leaks.  Yay! 

Clear oil can makes easier to monitor amount injected vs remaining. 
Each side used approx 1/2 of this "9" oz bottle

Left side (pilot side), RH brake 

Right side, RH brake...the fluid is up to 'T' at
firewall at reservoir on other side of firewall

Left side (pilot side), LH brake

Right side, LH brake...and "LH" fluid is also up to
 'T' at firewall at reservoir on other side of firewall
(this pic shows brake lines from center
 tunnel coming from the fuselage bottom) 

Firewall Forward Kit

Battery Charge Cord secured, new iPad ( 1 hr )

Routed and secured the battery charging harness/plug so accessible via the Oil Door.   Tried out new iPad Pro 11" for  first time in new mount.   Works great !  Added red stripes to Emergency T handle for canopy release.   Received from Aircraft Spruce the Bogart  Bogie Arm (one for RV-10 since same nosewheel, wheel pant)

Green  cap over plug for battery charging cable
 (came with Optimizer charger for LiFEPO4
batteries).  Accessible insider Oil Door.

new iPad in portrait mode...Garmin Pilot app, split screen. 
Note also the red stripes now on emergency canopy release handle.

iPad in horizontal mode... Garmin Pilot app, split screen.

Bogie Bar...same as sold for Vans RV-10

Firewall Forward Kit

Reiff Heater harness secured ( 2 hrs )

Secured Reiff Heater plug adjacent to Oil Dipstick for access via Oil Door.  Routed up from bottom of engine along engine mount tubing.  Added more hi-temp RTV to ends of connectors on Reiff harness to provide strain relief.   Received the iPad Pro 11" (to mount on RH side dash)  -- so lots of distraction today activating and "playing".  Loaded Garmin Pilot app for free 30 day trial to compare to Foreflight - seems excellent so far, and will be more compatible with Garmin G3X, etc (although Foreflight should work fine, too)

Reiff Heater plug secured at Oil Door opening

Secured to Engine mount tubes down to bottom
of engine.  I wrapped tubes w/ silicone
tape to avoid nylon ties wearing into tubes.

Firewall Forward Kit

Secure Reiff Heater harness ( 2 hrs )

Worked to secure connectors & harness for Reiff Heaters.  Used waxed cord (from harness assembly) to wrap each male to female connector (already snap fit).  Then lots of hi-temp RTV to secure harness to air box/oil sump on bottom of engine - per Reiff recommendation in instructions.  Added RTV to wire connections to sensor and each heater pad for strain relief.   Also cut 1.5" from 16" long SCAT hose to fit from baffle to oil cooler now w/ TCW air valve installed.  No pic, ref April 26, 2018 build log.

RH side with heater pad and sensor

LH side with heater pad.

Firewall Forward Kit

Optimate Battery Charger ( 2 hrs )

Received the "Optimate lithium LFP 4S 5A"  battery charger for the EarthX LiFePO4 main battery, Part No. TM291.  Recommended by EarthX specifically for LiFePO4 batteries.  Automatic test, charge, optimize (cell balancing), test and Maintain modes ( 10 steps).   Decided "making do" with Battery Tender Jr was not ideal.  Also finished RH firewall penetration with layers of firesleeve filled with hi-temp RTV per Sect 51-07.

10 steps shown along bottom

includes direct connection to battery terminals w/  plug. 
Performs all steps without interaction.  

bottom view of stuffed firesleeve

top view.   (messy to stuff  with RTV)

Firewall Forward Kit

Reiff Heaters ( 3 hrs )

Installed Reiff Heaters ( HotStrip Oil Sump Heater System, item HSS) so I can preheat in cold weather.   Reiff provides good instructions.   After trial fit to confirm location for each heat pad and the thermostat, I removed the paint with acetone, then scratched surface w/ scotchbrite.  The included epoxy is thick and tacky...kinda challenging to "corral".   Requires at least 48 hrs at 75 deg.

Reiff HotStrip Oil Sump Heater

removed paint on Oil Sump ( Lycoming IO-390 )

ready to epoxy on heat pads

added more tape after pic, since pad was gradually drifting downward
 ( gravity sucks !)

Firewall Forward Kit

Firesleeves (2 hrs)

Filled inside of firesleeves with hi-temp RTV after adding second firesleeve.   Used SS hose clamps  (vs Vans instructions to wrap with safety wire per Sect 51-07, Fig 3)   Applied self-adhesive label for new Oil Cooler temp control (butterfly air valve at oil cooler).   Stein Air did nice job.  Looks good -- but the camera shows a "white" outline around perimeter that is not apparent to eyeball.

LH firesleeve with hose clamps

 

stuffed full of hi-temp RTV.   (from cockpit side too)

applied new label for Oil Cooler temp control. [ camera shows
a "white" outline around perimeter that is not
apparent to eyeball]

Firewall Forward Kit

Firesleeve #2 and UHMW tape  ( 3 hrs )

While waiting for "anti-short bushings", I went ahead to insert firesleeve into RH tube.  With extreme difficulty (really sore hands!) I managed to get the firesleeve through to other side.  It took a couple hours!   The order of UHMW (ultra high molecular weight) tape arrived from Vans.  Per Sect 49-10, Fig 2,  I wrapped tape around VA-190 braided hose in couple locations.  Attached VA-119 hose to VA-190 hose with 2 cable ties per Sect 49-11, Step 4 & Fig 3.  Today, Rick Olson, builder of RV4 ( 2018 first flight) visited shop to check out my progress and discuss remaining details.  He's got lots of experience and was very helpful. Thanks Rick!

nominal gap for VA-190 to battery angle...
Vans builds have similar (or zero) clearance.

Arrow points to potential contact, now
covered with UHMW tape.  Circled area
is the 2 cable ties (also wrapped 1st
with UHMW tape)

Firewall Forward Kit

Firesleeve ( 2  hrs )

Per Sect 51-07, Steps 1-3 added firesleeve to wire & cable bundle at firewall pass-through (FF00001 Firewall Penetration Fitting).   Called Vans Prod Support - and Mitch Lock answered, President of Vans Aircraft.  He was filling in!  I told him my bundles were so tight in opening, I didn't feel I could insert the rubber firesleeve - especially the RH one.  He described how he encountered same issue, and used "anti-short bushings" instead when he built his RV14a.   Key is isolation of wires from metal edges front and back.   I ordered some 1" dia size (no local stores carry that size).  I inserted firesleeve in LH hole...with great effort, taking over an hour to push in.   I plan to use the bushings on RH side.   Both will be filled with hi-temp RTV, then wrapped with second layer of firesleeve.

Inside view showing success pushing firesleeve 1/4" past edge

Engine side.   Will fill with hi-temp RTV, then add
 another layer of firesleeve.

Engine and Firewall Forward Kit

Oil Cooler Air Valve, EarthX battery BMS ( 2 hrs )

Connected cable at air valve control arm.  Used -12 size cushion clamp on Engine Mount tube to mount a -3 size to constrain cable.   Added redundant collar (positioned to enable opening IF primary set screw loosens), and wrapped extra cable around arm.  Overall, works great.   Added spade connector to brown/blue stripe EarthX Discrete wire = "Discrete in 5" (GAD27, pin 13).  Will configure as "active low".   This enables BMS (battery mgmt system) to signal G3X display condition of overcharging, or over-discharging.

Full open.  Note cushion clamps on engine

mount tube holding cable in position.

Fully closed.  

Connected to BMS signal on EarthX battery (circled in yellow)

Engine and Firewall Forward Kit

Oil Cooler TCW Air Valve install  ( 3 hrs )

Painted semi-gloss black, mounted bracket to bottom IP for Oil Cooler Air Valve (from TCW).  Reference prior build log Feb 2.  Positioned valve on Oil Cooler to align with push-pull cable.   After routing cable through Firewall, I cut cable to length.  (Since not part of Vans instructions, it takes longer examining options and measuring 3 times).   Mounted air valve with (2) AN526 632R6 screws & MS1042 06 metal locknuts.   Sealed with hi-temp RTV.  Temporary attached cable---will finish tomorrow.

Cable control and bracket installed.   
Trying one of several labels Stein Air provided.

Ready to complete cable attachment.  But
first need to secure cable to engine tube with
Adel cushion clamps (where blue tape is now)