Avionics and Finish Kit

Canopy Warning & G3X config ( 3 hrs )

Received 24"x 36" cargo net w/ 2"x 2" mesh, 4mm bungee cord.  Came with 10 plastic hooks, but only using 5 (nice to have spares).  Good quality & seems good solution....for about $21 via Amazon.  Tah Dah !   I've been communicating several times with Vans builder support about the Canopy Warning file for the G3X.  Although followed Vans G3X Touch Canopy Warning Read Me file explicitly, I couldn't get my G3X to show the correct file after upload.   Vans finally clarified the Read Me file is wrong on step 11, page 2.  The G3X will display a file "RV14 G3XT options Config Rev 1" -- NOT the file "Canopy Warning R2.gca".   So...mine was working all along!   Otherwise trying to resolve issues with LH Joystick AP/CWS switch and Pitch Trim switch (RH is perfect!). Still consulting with Josh at Stein Air and Kevin at Tosten prod support.   At least some other Config issues have been resolved.

Added cargo net to hold loose small items

This is correct file for Canopy Warning upload to G3X.

Need to fix LH Joystick issues...

Getting more comfortable with set up via Config "folders"

Finish Kit and Avionics

Seat Belts and G3X Config ( 5 hrs )

Adjusted Seat Belt Harnesses for correct lengths for both my wife and I.   Workrd on G3X configuration/set ups.   Discovered LH joystick had Flap switch reversed vs RH joystick (RH agrees with panel mounted Flap switch direction).  So, contacted Stein Air, who consulted with Tosten  (grip source for switches and wiring).  Determined I could loosen switch bezel on grip, rotate switch 180 degrees.  Works correctly now.   Then I discovered the AP/CWS (autopilot/control wheel steering) switch is not working on LH joystick....and Pitch trim up/down is reversed vs RH joystick (but both have same Left and Right aileron trim movement).   Seems LH joystick has been assembled wrong...or connector on main harness in Fuse has a major problem.  Generated 5 pages of notes for follow up with Stein Air and Tosten after Memorial Day.

After loosening, then rotating small toggle switch
 on LH joystick, now operating same directions as
RH Joystick, and panel mounted Flap switch.
 (replaced red cap on toggle after pic)

Finish Kit

Joysticks and Boots ( 1 hr )

Installed LH Joysticks and both Boots.  In order to make it easier to install 3 screws at bottom of Boot, used some scrap thin, flexible plastic to make "keepers" or retainers.   Worked great.

Bottom side showing plastic retainers.   It would be a
bummer to loose screw into area below joystick! 
Sure did make attaching boot to Cover panel easier.

Boot attached.   Looks great.  I like to grey
 stitches accenting the black material.

Finish Kit

Seats, Harnesses, Joysticks ( 4 hrs )

Installed Seats and Seat Backs, Baggage carpet, and Floormats "semi-permanently" by positioning, then removing backing from self-adhesive Velcro strips.  Several required trimming to avoid screw heads  -- so more time consuming than expected.  Installed Joystick Boots (initially w/o Joysticks) to confirm fit.  Each secured with 3 screws that are challenging to access.   Removed RH Boot so I could install Joystick with 2 AN3-14A bolts.  Boot slips over top of control grip...but I'm dreading re-attaching w/ the 3 screws with the joystick installed...so saved for another day.   Pleased with interior -- the Crow 5 point harness looks great.

Checked Boot attachment prior to actually installing Joystick.

Tosten Joystick assembly (option from Vans) pre-wired.  Sweet!

Showing LH without Seat cushion.  Black strips are Velcro.

Finish Kit

Interior Panels ( 2 hrs )

Installed remaining panels in cockpit per Sect 42.   Added 5 nylon straps in baggage area for future (tbd...) cargo net.  Made from 1" nylon strap, cut to 6" lengths using "hot knife" so ends are "sealed".  Doubled over, and pushed hot nail through for mounting holes.  Included rubber washers to help spread the load.   Three are screwed into existing nutplates at rear panel, and at Flap Cover.  Two were riveted in toward front outboard areas.  I saw similar approach in VAF postings.  Plan to purchase a rectangular cargo net, with hooks in corners.   My 5th in center front may not be needed, but easier to add now than once in hangar.

3 of 5 loops created for holding Cargo Net 
( 2 on left were riveted )

2 at rear.  Can move lower or higher along screw positions.
(Not installing all screws now in panels, since removing
for Airworthiness Inspection soon)

Showing 2 of 3 along front.  Center one can be raised...tbd. 
Outer 2 needed to be riveted, since no nutplates near corners.

1st time Panels actually screwed into place

Engine

Fuel System Leak resolved...finally! ( 3 hrs )

Continued trying to find fuel system leak (not holding 30 psi air pressure).  Used "Mega Bubble Leak Detector" (blue fluid).  Supposed to detect micro leaks.  But I tested first on a joint gradually loosened - didn't seem much better than simple soap bubbles (maybe identifies leak at 1/2 rate, but my rate is approx 1/10).  Decided to try anyway...first re-checking firewall forward, then behind firewall.  When I added the liquid to the the pipe thread joint between filter and boost pump - I actually heard a light hiss with my ear about 6" away.  Never produced bubbles.  Neither did soap bubbles over last two days numerous times.   This was same joint I already re-did couple days ago.  But I tightened further another 1/3 turn...and Tah Dah !   Holding 30 psi for 2 hours !   Probably should have started with a mechanics stethoscope.  I now hate pipe thread joints !   Next, I started installing interior panel per Sect 43.  Installed Crotch belts for 5 point harness.

Installed inspection panels in baggage area, then added Carpet
from Flightline Interiors.  Perfect fit!

Installed wall panels and armrests from Flightline Interiors.
Added Crotch Straps.  Panels on floor haven't been screwed
down yet.

Engine and Avionics

Final Mounted Snorkel, LED interior lighting, and STILL can't find Fuel System Leak ! ( 4 hrs )

Removed Snorkel (air intake plenum) from fuel servo so I could remove tape at throttle interface (added more than year ago to keep engine "sealed").  Tightened four 1/4" bolts, then safety wired.  Ref 47-17 and 47-22, Step 15.  Also Configured Lighting in G3X for Red and White LED strips on canopy.  In Config mode, selected Cockpit Lighting, then chose PWM Lighting Bus 1, and Input 2 for White LED.  Set 0% at 0.0v, and 100% at 12V.  Same for Red LED, except Bus 2, Input 1.  (After pics taken, I revised setting 30% at 7v for each, so lower portion is easier to modulate...ie non-linear.  Pic shows original linear input vs output plot).    Still haven't found tiny leak in fuel system (approx 15 psi in 30 min) ...after another 3 hrs with multiple doses of soap bubbles .  Connected test equip at input to fuel filter, and got same leak rate - proving fuel valve is NOT source of leak.  Re-checked thoroughly every joint from Wing connection to fuel servo...with lots of soap bubbles.  NO joy!  Totally encapsulated w/ soap bubbles the mechanical fuel pump, electric fuel pump, and  Red Cube fuel transducer - trying to detect poor gasket, crack, etc. No joy.    So I loosened a connection on test equip, and was surprised although covered in soap bubbles - it didn't "indicate" a leak until I opened a much higher rate of 1 psi drop per 1-2 seconds !  Vans product support wasn't much help today...indicating soap bubbles should work. (Sterling did suggest dunking entire fuselage in my swimming pool, and look for bubbles ...ha !)  Another builder (Bill Lane, who's been very helpful) suggested I purchase gas leak detection "blue" fluid (available in hardware stores).  It may work better.   One advertises capable of magnifying micro-gas leaks as small as 0.65 oz/year into visible foam "cocoons".  Wow!  IF this doesn't work, I'll have to wait until Wings attached, fuel tanks connected - so I can test for leaks with aviation fuel.  VAF has tips to use white paper towels at connections, to show the blue stains from dye in avgas.

blue tape over drainage hole in plenum...with
hanging portion to insure removal prior 1st start.

 

 Red LED for night flights ....dimmed to medium intensity

White LED...good for general purpose in hangar, etc 
Red and White dimmer switches are in upper LH corner of panel

with Canopy raised, serves as overall interior lighting. 
This is at less than 1/2 intensity

Spent hours covering joints in soap bubbles,
inspecting w/ lights and mirrors.  No joy...yet.