Avionics

RG400 Coax antenna cables ( 3 hrs )

Routed RG400 coax from RH side Fuse at Comm whip antenna through to center tunnel.  Very difficult to pass cable through SB at transition to center tunnel...but eventually worked.  Crimped BNC connector on each end.  (Good videos from Stein Air and HomebuiltHelp , and EAA show how to do this successfully .   Then routed RG400 Coax cable from aft of baggage area through center tunnel up to IP for GPS WAAS antenna.  Crimped on TNC (threaded style  - and expensive at $23 vs $3.25 for BNC)  at antenna end.   Why Garmin uses this expensive connector at this antenna stumps me.   Also re-routed Static, Pitot and AOA air lines at IP.   As I routed coax cable nearby, I discovered perfect spot for a SB750-10 (not referenced in Vans instructions).  So I revised to route coax and these 3 lines together as shown below vs original pass over the vertical support.

coax cable prepped, then center pin crimped on

BNC connector crimped next,
added shrink wrap too

for Comm Antenna on RH bottom of Fuse

TNC (thread on stype) crimped for GPS antenna

routing/securing with static line next step

added snap bushing to vertical support, & re-routed air lines

Aft Fuselage

SB 18-09-17  ( 2 hrs )

My wife Nancy did great job w/ rivet gun under fuselage while I bucked from inside.  I laid down a layer of empty 2 Liter soda bottles, then bags stuffed full of plastic bags (both rescued from recycling).  And a couple pillows helped avoid crushing the elevator bellcrank / pushrod. Once in position it wasn't too bad...but due to my height, getting into and out of position from baggage area was challenging.   After we completed bottom rivets, I match drilled & deburred the four  #30 holes.  Used rivet gun & bucking bar to complete attachment to bulkhead.  Whew, glad that's done !

After riveting, showing notes for rivet lengths.

Layers of 2 L soda bottles & bags of plastic bags
 made "nest" to lay on while reaching way aft

Looks good!  It seems to stiffen skin significantly, bridging
before and after bulkhead as well as directly to bulkhead.

ta - dah !   glad this is done

Aft Fuselage

SB 18-09-17  ( 2 hrs )

Started Service Bulletin SB 18-09-17 "Cracking of F01478 Aft Fuselage - Forward Bottom Skins".  Examples of cracks discovered are here and here.    Deburred, dimpled, machine c'sunk and primed all pieces in "kit" I received Oct 10, 2018.  On bottom of Fuse, drilled out 10 rivets (all without extra drama...Yay!)  Cleco'd exterior plate in place.  Next step requires crawling inside Aft Fuselage ...aaarrggghhh!  I know it can be done...here's example.  My wife will use the rivet gun from beneath Fuselage.  I've remembered to brace the tail, so it won't suddenly become a tail dragger. 😜

page 1 of  good instructions w/ great dwgs

deburred, dimpled & machine c'sunk....primed next

6 rivets removed center area, plus 2 LH & 2 RH   J-stiffeners

yellow marks highlight missing rivets.
You can see shop head ends still on fuselage bottom

Diamond shaped "skin doubler" in place on bottom surface

Avionics

OAT wiring in Wing, GA 35 GPS antenna ( 3 hrs )

Fabricated 3 alum "brackets" to hold SB437-4's to guide/support OAT wire in LH Wing (from Wing root to 1st Access panel)  -- for when Wing assembled to Fuse.   Positioned Garmin GA 35 GPS WAAS Antenna on top Fuselage behind rear window.  Fabricated alum doubler referencing couple other RV14a builder logs about 1" larger than antenna.  Eric Rushing at Vans Prod Support confirmed their demo RV14's and RV10 did NOT use a doubler (but mounted close to stringer).   Reason I checked with Vans was Garmin installation recommends doubler w/  12 - 16 rivets.  Prior to mounting doubler removed primer on inside Fuse skin for best ground contact (Garmin instructions for G3X/GA 35 antenna).  Note: GA 35 antenna is Serial No. 144,789.  P/n 013-00235-00

single rivet w/ epoxy located/mounted Snap Bushing supports.
 When Wing mounted to Fuse, will route OAT  wire via these 3

Doubler prepped.   After pic, changed to use lock nuts
instead of these nutplates shown

Used doubler to match drill Fuse skin

deburred, ready to mount antenna

prior to actually tightening screws.

prior removal primer for doubler grounding

Used acetone to remove primer for better grounding
TNC connector (not BNC) ready for coax cable.

Avionics

Static, Pitot & AOA connected, Comm Antenna installed ( 4 hrs )

Connected Static (red), Pitot (white), & AOA (blue) lines to G3X at GSU 25 and to G5.   (note: blue AOA line goes only to GSU 25).  T fittings worked well.  Next, enlarged holes at Comm antenna mount on bottom RH side of Fuse and F-00020 Doubler per Sect 55-05, Fig 1 and Sec 28-02.  Mounted with 8-32 flathead SS screws.  Comm antenna is Comant C1 122 whip, VHF Com 118-137 MHz, Serial # 556913.   Also completed riveting second Joystick Boot w/ just delivered 8 more AACQ 4-3 rivets.  Good progress today, plus this morning I attended EAA Chapter 129 breakfast where my friend Rick Olson displayed his just built RV-4.   He's really enjoying every minute flying, w/ approx 6 hrs of 40 hr Phase 1 completed.  Very impressive !  Congrats Rick !

Static (red), Pitot (white), and AOA (blue) connected. 
Installed back-up battery on G5 also

Comm antenna mounted

Doubler plate on inside

Rick Olson with his RV-4.  He painted it too.  Terrific!

Avionics

GAP 26 wiring ( 1 hr )

Tightened and torqued gnd bolt.  Bundled wires along with alum tubing.  Sent email with pics to G3Xexpert@garmin.com asking if OK to attach wires & cable ties to alum tubes due to heat conducted from Pitot.   Probably need to re-do with wires & cable ties not touching alum tubes. [Update Dec 17: Garmin's Mike Huff, field service engr (contact G3xpert@garmin.com ) says no problem with wiring and cable ties attached to alum tubing.]  Also replaced orig USB charging port on IP (2.6 amp) with upgraded/new one provided by Stein Air w/ 4.8 amp capacity.   This will maintain iPad when Foreflight/GPS running, yet is below 5 amp CB.  Stein Air provided free - since all recent panels are equipped w/ the higher version.
 

view looking outboard

view looking forward.  

Avionics

Gap 26 heated Pitot  installed ( 3 hrs )

Trimmed 3/16" OD alum tubes to 8 1/4" on GAP 26 heated Pitot (Garmin instructions note min 8" to avoid excessive heat conducted into plastic fittings/tubing).  Removed Pitot mast from bottom LH Wing.   Lined up holes in Pitot to drill clearance holes for 6-32 SS flathead screws.  Then countersunk, and shortened screws to 5/16".   Re-installed mast, then slid Pitot into place.  Connected AOA (blue) and Pitot (white) air lines using the newly released fittings purchased from Stein ( sku P-518 feature 3/16" one end, 1/4" other end).  Sweet!   Connected 14ga pwr wire, added gnd wire (also 14ga) to pairs of wires per Garmin instructions.  Wiring not yet bundled or protected, nor is gnd bolt tightened.  Overall, a lot of work, but pleased with results including the flush screws mounting Pitot.

trimmed to just 8.25".   Test fit push on fitting.

Removed mast from Wing.  At first I forgot the extra plate
is there to accommodate dimples in wing skin
when mounted from inside.

Ready to insert

Countersunk holes for mounting screws.

top view, inside.  NOTE: wires and tubing not
 yet bundled or protected.  Gnd bolt is loose.

View from adjacent bay with aileron bellcrank.  NOTE: wires
and tubing not  yet bundled or protected.  Gnd bolt is loose.

not a great pic...but with screws installed