Avionics & Finish Kit

Rear Window and Joysticks ( 6 hrs )

Completed switch of Black wire in Pin 1 with Orange wire in Pin 2 (Orange is now Pin 1, Black now Pin 2) on LH Joystick Tosten grip.   Now the pitch trim works in correct direction, equal to RH Joystick Tosten grip.  [ seems out of synch revisions to Common Fuse Harness and Tosten grips are culprit - or Stein Air just plain messed up LH harness assembly ]    And confirmed Canopy Warning works while stationary, so tightened micro-switch position.  Final test will confirm audible warning starts above 1700 RPM. (...once engine is running).  [ note: Vans has error in Read Me file:   file name that appears on G3X screen when uploaded is "RV-14 g3xT options config rev1"  NOT the file in their instructions "Canopy Warning R2.gca.  Took several emails & calls to Van's builder support before they finally noted that is how Garmin shows the Canopy Warning file.  Completed jumper wire (yellow) from Pin 9 in LH Joystick (actually mating connector in Common Fuse Harness) to Pin 9 in RH Joystick  - so now AP/CWS switch works on LH Joystick/grip.  [ this was option proposed by Stein Air, since essentially the original wire takes same route, but very circuitous - and huge challenge to determine where the fault was...)   Finally, the Rear Window is installed.  Nancy climbed into baggage area so she could assemble the washers and nuts on inside while I added screws from outside.   Messy job getting sealant into gap between Aft Fuse and Window, but got 'er done.  Thanks Nancy!   Tip:  remove inside plastic covering on Rear Window prior to installing.   The fore/aft brace to Rollbar is close to window, making removal difficult.  Sect 38-04 Steps 5-9 instructions are good, but don't mention that detail.  Seems obvious after installing of course!

Orig positions of wires in LH Joystick grip

After switching Orange and Black 

After several fixes with harnesses, re-assembled Interior. 
(Didn't mount iPad on RH side in RAM mount for this pic)

And with G3X, G5 backup, AP and Radio all "on"

Rear window mounted. Sure glad Nancy fit into baggage area

Other side....
Yay! ...getting ready to move to hangar! 
So I can put the Wings and Tail on (and
then lots more Avionics to Config, Test, etc)

Avionics

Discrete #3 for Canopy Warning, LH Joystick fix (3 hrs)

Received extractor tool from Stein Air so I could switch wires in connector J244 on GEA24.  Switched wires at Pin 41 and Pin 42, so Purple/Blu wire now at #42 = Discrete #3.  (and Purple/Grn is now at Pin 41, for Discrete #2).  Needed to align Discrete #3 with code within Canopy Warning program from Vans  (recently uploaded into G3X).   Also checked all 9 pins in LH Joystick connector:  confirmed need to switch wires in Pin 1 (black) and Pin 2 (orange) for correct Trim Up vs Trim Down to be same as RH Joystick.   Kevin (owner of Tosten grips) has been helpful, and is sending new Molex pins to crimp on when I switch wires.   Confirmed AP/CWS switch failure to work is not in joystick, but LH Common Fuse Harness.  Josh at Stein Air helped explore fix.  Seems best option is to install jumper from LH 50 pin connector Pin #3 to RH 50 Pin Connector Pin #18.   OR...run wire from Pin 9 in Common Fuse Harness at LH Joystick to RH Joystick Pin #9 wire (ie joystick to joystick).  Learned this wire sends signal to AP servos...not IP...so not connected to anything at panel.   tbd....!

J244 connector at GEA24 partially dis-assembled, but prior
 to swap Purple/Blu with Purple/Grn. 
 This aligned Discrete #3 w/ Canopy Warning program.

Success!  Canopy Warning appears as "Check Canopy".  Flashes
 for about 5 seconds, then steady on.  Above 1700 RPM, should
also hear audio warning.   (Other warnings due to engine
 not running, etc.) [sorry- hard to get focused pics of display]

Notes documenting Pin and wire color

for LH Joystick

Avionics

Instrument Color Markings ( 3 hrs )

Surprised limited info in Lycoming manuals, or via Vans, or VAF postings to recommend green, yellow and red color markings on G3X instrumentation.   So I gathered from those resources as much as possible, consulted with local experts Terry Moushon (Tech Counseler and builder RV10) and Bill Lane (RV 7 builder).   Lycoming test results for my engine were helpful (showing max and min Limits on several parameters).  Included pics below from powerpoint I created.   Setting up on G3X is almost fun.  I can refine these after first flights...but seem good starting point.

Camera doesn't focus well on display.... 
W/o Wings attached, don't have fuel tank senders connected, etc.

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)

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.

Engine and Avionics

EGT sensors connected ( 2 hrs )

Per Sect 48-07,  Steps 1-3 completed wiring connections to 4 EGT sensors.  Added safety wire to hose clamps per Alcon Tempest instructions per their recommendation.

front Right EGT sensor connected

back Right EGT sensor prior  pulling
protection sleeve over connections

Overall pic of Right side.  ( note: Spark plug wires not
connected for LH magneto...still have desiccant plugs installed)

Left side.  ( The automotive plugs are installed on bottom
 on this side for PMAG electronic ignition)

Engine

EGT sensors (and more Fuel System leaking ? )  ( 3 hrs )

Back to trying to find leak in Fuel System !  At first, thought yesterdays leak discovered and repaired completely solved Fuel System "leak"...but after 1 hr, the 30 psi air pressure slowly dropped.  So today repeated - and now won't hold pressure for more than couple minutes.  Redoubled efforts with lots more soapy suds...thoroughly covering every possible joint or leak path -- No joy.  To confirm not test equipment, I positioned Fuel Valve to OFF...and it held pressure.  So considering if internal leak in valve from LH to RH side. But tested for air transfer to RH side (tube added to fuselage fitting, ending under water...no bubbles!) -- again No joy.   So tomorrow I'll try to isolate (remove hose to engine fuel pump, cap and test that section)...with more soap bubbles.   Meanwhile installed all 4 EGT sensors Type K thermocouple (from Garmin G3X sensor kit, Alcor Tempest #86255, which is Garmin #494-70001-00).  Reamed holes (pleased already drilled in exhaust tubes) w/ #30 reamer since press fit.  Need to finish wiring connectors, add safety wire.

re-checking for leaks in fuel system...

getting frustrated....total immersion seeking possible leak
in "red cube" fuel transducer itself, as well as connections

EGT sensor installed, still need to connect wiring.
Sensor is press fit into #30 hole...so tight and leak free

Left side  (not yet connected to brown thermocouple wires

Right side

Added pic of sensor for reference.

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!

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.

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

Avionics

iPad Mount installed ( 1 hr )

Received iPad mount for Instrument Panel.  Ordered from Sporty's this new "Robust Universal iPad Suction Cup Mount" ( a good value at $40 ) and Ram circle base.  Replaced suction cup with Ram base permanently mounted with four 6-32 screws and locknuts.   The 3.75" arm allows lots of positions.   Pending delivery of  11" iPad Pro...

Vertical orientation

Horizontal orientation.

Partially blocks "glove box", but easily moved for access.