Finish Kit and Avionics

Misc, fire extinguisher & hangar ( 3 hrs )

Trying to complete as many tasks as feasible prior to moving to hangar.    Checked all 5 sets of  Kit instructions for any "loose ends".  A few final torques, replaced temporary nuts, etc...but nearly all I can do has been completed. Still lots of post-its on pages identifying actions once Wings and Tail are assembled onto Fuse.  Still pending Exhaust assembly as last step (to keep engine closed from moisture as long as practical).   Made 2 pairs of wheel chocks from scrap 2x4's.  Ordered Amerex A344T, 1.25lb Halon 1211 Class B C fire extinguisher (reviewed VAF for recommendations, pros/cons) for cockpit.   Expensive at $199, but best option.   Also purchased Amerex B500, 5lb Dry Chemical Class A B C fire extinguisher for hangar for $53.  Checked performance of GD-40 CO Detector: OK, shows warning on G3X display w/ audible.  Confirmed Flaps move down with switch acutation "down".   Starting Config of G3X, but most requires Wings and Tail assembled...so will need to wait until later in hangar.   I now have keys to hangar at Mt Hawley (3MY).   Will need to hang some lights...

cotter pins added 4 places on tailpipe hangars.  Followed
orientation  per Vans instructions - which made bottom 2
much harder to install cotter pin.  

New 2x4 wheel chocks for hangar.
 (too tall once Wheel Pants installed)

Just 1 light in hangar...so I'll be adding more!

Finish Kit

Data Plate, Vinyl N number, Experimental label ( 2 hrs )

Applied EXPERIMENTAL vinyl lettering to rear bulkhead panel (ie rear of baggage compartment).  Purchased last year the EAA Homebuilder's Step by Step Certification Guide, and this vinyl label is included.  It's really valuable with great instructions, and all forms needed with examples shown -- highly recommend to all builders.  Attached new Data Plate to LH side Aft Fuselage under leading edge Horiz Stab using 2 flush blind rivets.    Applied 3" vinyl N number to Aft Fuselage (both data plate and N number letters bought via Net Engravers).  Easy to apply, and although temporary (until I have airplane painted), I think they look great.

required EXPERIMENTAL label done

Data Plate ...done.

showing location of Data Plate. 
Similar to most Certified airplanes

easy process to transfer vinyl letters to Fuselage

these 3" letters meet Experimental regs...will do until I have plane painted

impressed by quality and strength of adhesion.  

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.

Finish Kit

Replaced Left LH master cylinder ( 2 hrs )

Replaced LH master cylinder on Left side with one Vans shipped free.  [ After initial installation, when I pumped this brake, bubbles in the line would immediately appear and the brake would get soft...all others were OK.   No leaks anywhere...so appeared to be ingesting air.]  Drained per gravity the brake fluid, then disconnected the cylinder.  Please no drips.   Transferred original elbow fittings, and installed new cylinder.  After refilling -- No leaks, No bubbles, and stays firm.  Hooray!   It was a defective cylinder (probably at shaft seal) sucking in air on back strokes.  Rare, but another builder had reported same issue in VAF forums a few years ago. 

Left master cyl is slightly darker finish vs
original and mate on right side

Avionics

Power to Instrument Panel ( 2 hrs )

I had a 2 week delay powering up my panel when I discovered a critical wire running power from Master Relay (Battery Contactor Relay) to Main Bus was missing.  I'd connected everything per Vans instructions, and connected everything from Stein Air for my panel & related.  My mistake was not looking at overall electrical schematic.  Stein Air picked worst timing for me to move to new offices, then another week at Sun n Fun.   Eventually I connected (pun intended!) with Josh at Stein Air, and we quickly diagnosed I needed a 4.5 ft 8AWG wire from Master Relay on firewall to the Aviation Bus Bar (which connects to Main Bus at CB panel).  Josh provided the wire with appropriate ring terminals.   I told him they should provide notes on schematic identifying what Stein Air was not intending to provide.  My mistake was assuming I had "everything" needed to complete the installation.  Now it seems obvious!   I ordered from Aircraft Spruce a 2 pc Firewall Shield (#61-275 ) and Silicone Grommet size 5/16 (#11-13460 ).  I didn't want to re-do the firewall penetration, & here,  but instead add specific hole for this 8 ga wire.    So NOW I have full power with 1st time I've powered up G3X, G5, GTR 200 Radio, and GMC307 autopilot.   Lots of tuning to do, and missing connections to most lights (wings, tail, canopy), ADHRS, etc.

Powered up panel !

New firewall penetration.  Silicone gromment under shields.
  Wrapped wire with silicone tape to make tight fit in grommet,
covered in hi-temp RTV.

view showing original firewall penetration just above.
 Master Relay on lower left, with Starter Relay below it

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.