Monthly Archives: October 2022

You are browsing the site archives by month.

VS Attach and Misc.

Much of the finalized assembly was not photographed in-progress, as fabrication of the parts was generally covered in previous posts.  Plus I really wanted to get done without taking further time on the website. A greater reliance on video content was made as the build headed for completion.

VERTICAL STABILIZER

Here the vertical stabilizer was being attached to the empennage – hopefully for the last time.

 

 

 

 

I made this custom NAV antenna bracket many moons ago. In retrospect, I would probably forgo this bracket and mount the antenna directly under the fuselage.

 

 

 

Anyway – here was the final connection and covering by the VS cap.

 

 

 

 

The left photo shows the Suntail Strobe/Nav wiring exit between the rear fuselage and the rudder bottom.  On the right is the original elevator stop replaced with a much heavier and larger alternate means to comply with Service Bulletin SB18-03-30 from Vans. This modification prevents over-rotation of UP elevator.

 

 

Following attachment of the rudder bottom, intersection fairings around the VS and HS were installed. Thin rubber edging protects the HS paint from the elevator trim covering. Note the elevator horn to elevator push rod assembly in the upper right of the first photo.

 

 

 

This photo shows a taut line extending from the main wheels at ground level to the rear tie down point.  This confirms the COM1 antenna will not scrape on the runway during takeoffs or landings.

 

 

 

 

BATTERY BOXES

The Odessey 680 batteries were secured with a Delrin-like polymer frame with a felt underlayment for protection.  Here are the components before assembly.

 

 

 

The final configurations of the battery boxes, Artex 1000 ELT, and the Garmin GTX45R transponder/ADSB behind the baggage bulkhead is show here.

 

 

 

Interior Panels

Now that the airplane has been moved to the airport and wings attached, final painting and installations can proceed.

Interior panels from Aerosport Products were primed with PPG DP48LF white primer.  Later the panels were painted PPG Concept Boeing Grey.

 

 

 

The foam backed, fabric material was glued into place on the Aerosport headliner with contact cement by professional auto specialists. (Don’t ask why I did not do this myself). The backing fiberglass was then fitted with Velcro strips and attached to corresponding strips on the canopy.

 

 

More views of the overhead console and installed headliner..

 

 

 

 

The left photo shows fitting the map pockets on the forward interior panels prior to prime/paint.  The right photo shows the baggage bulkhead after painting.

 

 

 

A Blue Seas power outlet was fitted onto the baggage bulkhead.  A 10A fuse and toggle switch for directing trickle charge power to either PRI or SEC battery were installed with switch guards.  This outlet is not intended for ever jump starting the aircraft.  The required EXPERIMENTAL decal was installed on the upper bulkhead cover.

 

The lower bulkhead cover was fitted with UHDP wear blocks for the rear shoulder harness cables.  The right picture shows a rear interior panel with the air vent cover installed.

 

 

Preparation of the Aerosport dashboard cover included installation of covers for the panel fan outlets and trimming the edges for fit.  After trim, I used my fledgling sewing skills to dress the edges against fraying.

 

 

The center console and control stick wiring was completed and tested.  Labelling of the jack ports was with a Brother P-touch. I would have preferred a laser etched alternative, but maybe than can be a future project.

 

 

 

The dashboard cover was secured with 1″ and 2″ Velcro strips.

 

 

 

 

Final dashboard cover, center console and control sticks installed…

 

 

 

 

Front and rear footwell carpet…

 

 

 

 

Rear seat and baggage compartment carpet…

Wing Attachment (3) and Misc

Finish configuration of wing root covers required installation of a few system components.

The rear spar bolt was an AN6-11, anchor nut and cotter pin. The wing root fairing supports are held primarily by LP4-3 pull rivets.

 

 

 

A custom fuel line, filter and shut-off valve from TSFlightline was installed.  This configuration should allow the filter to be removed for annual inspection without the need to completely drain the tanks.

 

 

The massive and high precision bolts (NAS1309-58 and NAS1306-58) were tightened with the nylon insert (AN365-918 and AN365-624) lock nuts and regular/thin washers to expose sufficient bolt threads.  The torques were 100 lb-ft and 20 lb-ft respectively

 

 

The Stewart-Warner IE-F-385C (right) fuel sender was attached with NAS180-2-0808 (8-32) hex head bolts and Permatex Aviation Forma-Gasket sealer compound.

 

 

Fuel sumping valves were installed and fuel vent lines were fabricated from 1/4″ stainless tube.

 

 

 

Lastly a Garmin GTP59 air temperature probe was installed near the first inspection port.  This last run allowed the wire bundles to be consolidated and attached via CPC-24 connector to the fuselage.