Finish Kit

Wing Root Fairings ( 4 hrs )

Completed LH & RH Wing Root Fairings per Sect 41-04, Steps 1-14 (except Steps 6-9 requiring Wings installed ).  Completed deburring, then dimpled all holes (for #8 screws, and rivets).  Riveted 18 stiffeners onto Top Fairings using rivet gun with back rivet tool and metal back up plate - really easy.  Marked and bent Lower Fairings to conform to Wing leading edge.  Been awhile since I used these set ups...kinda "fun".

ready to dimple w/ C Frame

back riveting

 

trial fit on RH side Fuselage

Finish Kit

Torq Seal and Wing Fairings ( 2 hrs )

Did some "clean up" of some loose ends in Fuselage:  climbed into Fuse and managed to twist around until I could just barely reach nuts on 6 bolts for Engine Mount to apply torq seal.   Then moved into baggage area to confirm torques and apply torq seal to all fasteners on Elev pushrod bellcrank mount.  Nancy assisted me bending and unbending my 6'4" frame into this tight space.   Next I jumped to Sect 41-04 to Final Drill #17 holes, deburr all edges and holes as prep for LH & RH upper and lower Wing Fairings.

Firewall Forward Kit

Sender Mount, etc ( 3 hrs )

Installed Sender Mount, adding fittings and hoses VA-102 and VA-119 (from Sect 49-11, Fig 2) prior to bolting onto Firewall.  Primed and painted "stainless steel rustoleum color" the Garmin Manifold pressure sensor bracket -- then mounted to Firewall.  Installed WH-P25 AWG Ground Strap, too.   Installed first Adel clamps (hose above, battery cable bottom) using safety wire trick.  Worked, but awkward.  May invest in speciality too for adel clamps since lots to do....

upper LH corner is MAP sensor bracket.

Firewall Forward

Starter Solenoid and Master Relay ( 3 hrs )

Started FF Kit ahead of engine delivery -- so I could mount components to Firewall easily.  Installed Master Relay and Starter Solenoid w/ connected wires per Sect 43-04, Steps 1-4.  Also partially assembled Sender Mount after first priming and painting.

Primed, painted "stainless steel".  Trial fit fittings.

Firewall Forward Kit

Prep for FF Kit / some Pushrods from Finish Kit ( 2 hrs )

Minimal shop time Jan 8 - 10 while working phones and emails with Vans, Stein Air, Aircraft Specialty, and Flightline Interiors.   Vans sending a few items missing/wrong in FF Kit (from 8 pages, only a few).   Working with Steve at Aircraft Specialty for hose upgrades:  planning to replace FF00014 hose with hose specifically made for the single P-Mag on my Lycoming IO-390 for the manifold air pressure sensor (from engine to both sensor and P-Mag).  Very helpful and high quality components (I installed their alum tubing fuel lines, hoses inside fuselage last year).  Working with Nick Millard at Stein Air to finalize Panel design.  They're sending bunch of components now (Auto Pilot Servos, ELT, etc) that I can install while waiting engine delivery.  Over several months (off and on) from concept to final design, Nick has been very helpful getting the Panel just right.  I've also launched Seat and interior development with Abby at Flightline Interiors.  Been a pleasure to get started, leveraging her experience.   Only shop work was building 2 Flap Pushrods per Sect 41-02, Steps 1-5, and 2 Stick to Torq Tube Pushrods per Sect 41-06, step 1.

3rd from bottom hose needs modified to work with P-Mag. 
Planning to replace with hose from Aircraft Specialty.

Latest, maybe final design of VFR panel. Will be black,with white engraved 

labels.  Toggle switches.  Moving T/P/M controls to bottom of panel, 

vs Vans orig design with addition below Panel (improves my knee room !)

Abby at Flightline Interiors had example of
Vinyl seat with fabric insert very similar to
our concept.  Not this logo w/ "pink" color...

Firewall Forward Kit

Firewall Forward Kit Inventory ( 9 hrs )

Rec'd FF Kit on Jan 4 via Fed Ex in 3 medium size boxes.  One weighed 60 lbs, but other 2 were closer to 10lbs each.   Spent several hours on Jan 4, 5 and 6 upacking, counting, and storing parts from 8 page list with my wife's assistance.  Vans missed only a few parts out of a very long list, which I'm requesting corrections.  Now I have the rubber mounts to hang the engine soon (to start 2 month compression set prior working on cowl alignment).  Vans and Lycoming confirmed build date is Jan 22, so not long before receiving.   I also have throttle cables so I can mock up position just above bottom edge of panel, vs original just below.  This provides knee room to better accommodate my 6' 4" frame.  I'm working with Stein Air on final details of panel layout...and they've recently ordered all the Garmin avionics.

small parts fit into original storage boxes.

misc parts

exhaust parts in box, spinner beside, baffles,  & ducts

Finish Kit

Brake Lines ( 3 hrs )

Received from Van's the AN365-524 nuts to replace MS21083  N5 shear nuts on the Gear Braces per Sect 29-03 -- torqued per Sect 40A-04 (Fig 4).  See entry dated Dec 21, 2017.  Completed LH & RH Brake Line installation per Sect 40A-10 Steps 1-8, which was last page of Sect 40A "Tricycle Gear & Engine Mount".  Conforming 1/4" OD alum tube to align with Leg, then wrap around at bottom was "easier" than imagined.

straightened tubes, added various
pieces, then flared each end

 

 

will be covered by aerodynamic Leg fairing

route stays inside profile of  Wheel Fairing