Avionics

GTR 200 Radio and GMC307 autopilot installed ( 2 hrs )

Installed tray for GTR 200 radio (holes drilled, spacers done months ago).  The 6 screws holding tray were challenging due to tight/awkard position, so required much more time than expected.   The radio itself slid into position easily.  Then installed GMC 307 Autopilot with simple retention on IP itself.   Finally, tightened connectors on backside of each.

radio tray installed, ready to slide in GTR 200 radio

GMC 307 Autopilot installed above GTR 200 radio.  Inserted
emergency canopy release lever - which needs painting after
 rotating handle 90 deg

Release lever in place, connectors installed,
wiring protected.  Good to go!

Avionics

BNC connector, Wiring in central tunnel  ( 3 hrs )

Crimped BNC connector to WAAS GPS antenna coax.  Connected to Garmin 20A unit on sub-panel. Completes all 3 BNC and 1 TNC connectors (4 out of 4 successful, so didn't need extra BNC ordered...yay!)  Completed bundling & securing wiring from central tunnel up to IP.   Maybe done with cramming under dash...assuming all connections check A-OK,  and no air leaks or brake line leaks.

Completed securing RH wiring and brake lines

LH wire routing and protection

RH side wire routing and protection

low angle view under "dash"

Avionics

Discrete #3 (now Discrete #2) connected to Fuel Pump, etc  ( 3 hrs )

Update 5/29/19: needed to switch Fuel Pump On to Discrete #2, so Discrete #3 could be aligned with Canopy Warning.  #3 is locked in by Vans program for Canopy Warning uploaded into G3X.  So I switched Purple/Grn wire and Purple/Blu wire in connector J244 at GEA24.  This aligns Purple/Grn to Pin 41 and Discrete #2.   And Pin 42 = Discrete #3 for Purple/Blu wire.

Crimped connection Discrete #3 (now Discrete #2) wire to Fuel Pump Power wire adjacent to pump in center tunnel.  Will provide notice on display "Fuel Pump ON".  Bundled & protected LH Common Harness + GPS cable + Static/AOA/Pitot air lines + Discrete #3 #2 inside center tunnel and up to back of IP.  Installed nutplates so I could use -12 size cushion clamp ( seems nutplates should have been done via Quickbuild, since not otherwise denoted to do earlier)

yellow denotes adel clamp (nutplate had to be installed via blind rivets at this
stage).  Red wire is Fuel Pump power, which under top cables is joined to
Discrete #3 #2 wire (purple/green stripes)

progress bundling LH Common Harness, other wires & air lines

from center tunnel up to IP.  Repeat next for RH side.

Avionics

GPS antenna coax ( 2 hrs )

Routed RG400 coax from GPS antenna along center Aft Fuse to 1st bulkhead, down to bottom then forward.    Shared same route as Static air line on LH side, so replaced orig cable ties as I added coax.  Due to awkward reach and position required, got lots of isometric exercise.  Good news - don't expect to be working inside Aft Fuse any more.  Again, my wife Nancy was key to helping me into and out of position in baggage area ( I'm too tall - and don't bend so easy these days)

joined with LH Static line along bulkhead

joined w/ other wires along center

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