Purpose

As we get closer to the completion of the kit, there are many random things that we must “finish up.” This list is nothing more than a random brain dump of those items as we think of them. On occasion, we’ll organize this list a bit. When we complete an item, we’ll move it from “Future” to the day that we completed the item.

TODO List

(A=Anyone, J=Jeremy, S=Sam, L=Lucas, JS is Jeremy & Sam)

Before First Flight

• Perform another conditional inspection (up close)
• Install inspection panels
• Create heat shield for cap
• Mount go-pro cameras
• Test mounting position with actual taxi and review video
• Ensure we capture audio from intercom somehow
• Clean dust from windows
• Clean finger prints from instruments
• Install GoPro dash panel mount -?
  • How do we make sure that the GoPro mount is straight?
• Avionics
  • Put a tick mark at what I consider to be the minimum maneuvering speed
  • Make sure that auto-pilot is turned off
• Secure bottom flanges of windshield -?
• Engine
  • Adjust prop for 2800 RPM static -M – Verify
• Determine max RPM during run-in period, first 15 hours. Manual says 80% power after takeoff. 2800 RPM (max continuous) would be 2,240 RPM. 3300 RPM (max throttle) would be 2,640 RPM. - Robert says 3,300. He also said, however, that no special run-in process is needed.

Future

-Purchase pump for hanger

• Complete Interior
  • Create glare shield cover -S
  • Determine how to mount carpet
  • Determine what carpet to order
  • Order Carpet
  • Carpet the interior

Notes

• Taxi/Landing Light Lens Mount = MS21047L3 Nut Plates with AN525-10R7 screws

May

28, Friday

• Left Door Frame

27, Thursday

• Right Door Frame

26, Wednesday

• Get wing cradle from Greg and put in new hangar

25, Tuesday

24, Monday

23, Sunday

22, Saturday

• Work on means to determine Vx/Vy

21, Friday

• Work on means to determine Vx/Vy

20, Thursday

19, Wednesday

18, Tuesday

• Discuss testing phase with Al

17, Monday

16, Sunday

15, Saturday

14, Friday

13, Thurdsay

12, Wednesday

11, Tuesday

• Verticial Stabilizer

10, Monday

• Left Wing: Finish
• Left Wing: Take to airport

9, Sunday

• Left Wing: Rivet top skins

7, Friday

• Left Wing: Cut pitot/aoa tubes to length
• Left Wing: Install fittings onto pitot/aoa tubes
• Left Wing: Run pitot/aoa lines
• Left Wing: Wire pitot tube heat
• Left Wing: Clean up trailing edge items (wire, fuel lines, pitot/aoa lines)

6, Thursday

• Left Wing: Determine how to install pitot/aoa lines
• Left Wing: Finish inboard skin
• Left Wing: Find/Borrow flair tool (37 degree)

5, Wednesday

4, Tuesday

3, Monday

• Left Wing: Cut Wing Tips
• Left Wing: Drilled/Fit inner curved skin
• Left Wing: Fuel Supply Hose
• Left Wing: Fuel Return Hose
• Left Wing: Rivet 2x inside rivets for strut L-angle

2, Sunday

• Mount Magnetometer in Left Wing
• Left Wing: Fit/Drill/Debur Inboard Skin
• Left Wing: Cut hole for fuel return line

1, Saturday

• Cut/Install rubber baffle material
• Measure/Mark location for Oil Door
• Determine new spot for Magnetometer (Left Wing)
• Left Wing: Drill/Debur top skins to spar

April

30, Friday

• Cut/Install Metal Baffles
• Cut/Install Pitot Tube in Left Wing
• Left Wing: Fit fuel tank

29, Thursday

• Create Pitot Tube doubler

28, Wednesday

• Left Wing: Drill spar out to #30, #20
• Left Wing: Debur skins
• Left Wing: Cortec ribs and bottom spars
• Left Wing: Rivet bottom skins

27, Tuesday

• Left Wing: Fit bottom skins
• Left Wing: Create L-angle supports that were missing from kit (W8-1)
• Left Wing: Drill spar out to #40

26, Monday

• Left Wing: Rivet structure

25, Sunday

• Wire Strobe Light to Left and Right Wings
• Right Wing: Final inner wing skin fit
• Right Wing: Take to hangar
• Left Wing: Rear Spar
• Left Wing: Cleco Structure
• Left Wing: Root Rib Assembly

24, Saturday

• Boot Cowling: Put it nut plates for cowling
• Right Wing: Grounding of fuel sensor and fuel tank
• Right Wing: Stop Drill the crack in the wing tip
• Right Wing: Glue small crack in wing tip
• Right Wing: Rivet wing tip

23, Friday

• Cowling: Put in nut plates
• Put final clamp on fuel supply from fuel switch to fuel cut-off valve
• Put final clamp on fuel supply firewall side of bulkhead fitting
• Right Wing: Initial fit of inner wing skin

21, Wednesday

• Fit Cowling

20, Tuesday

• Final Mount Fuel Cut-off Valve
• Plumb fuel supply
• Plumb fuel return

19, Monday

• Right Wing: Replace hose clamp with crimp type
• Right Wing: Support return fuel line
• Right Wing: Rivet remaining skin
• Right Wing: Anchor Landing/Taxi/Strobe Light Wires
• Right Wing: Remove unused 16AWG wire from wire loom
• Right Wing: Install strobe light mount (install strobe light after wings mounted to plane to prevent damage)

18, Sunday

• Right Wing: Rivet missing rivet in bottom L-angle
• Right Wing: Leak test fittings/hose
• Install new fuel supply bulkhead fitting

17, Saturday

• Trim metal landing/taxi light support bracket to fit
• Trim landing/taxi light lens
• Install taxi light into light mount
• Rivet landing/taxi light to wing
• Right Wing: Wire landing light wing tip to light
• Right Wing: Wire taxi light wing tip to taxi light
• Right Wing: Install Molex connector to strobe light
• Right Wing: Install Molex connector to wing tip wiring
• Right Wing: Dimple both fuel access panels
• Right Wing: Install blind nuts in fuel access panel
• Right Wing: Final install fuel tank
• Right Wing: Install supply fitting
• Right Wing: Install return fitting

16, Friday

• Determine how to do AP servo mounting
• Order Pitch/Roll AP servo mounts from Dave Beaulieu

15, Thursday

• Get solid rivet tools from Lucas
• Learn solid riveting techniques
• Learn dimpling techniques
• Right Wing: Mount lens

14, Wednesday

• Fuel Tank (Right): Install fittings
• Fuel Tank (Right): Leak Test Fuel Sender Seal

13, Tuesday

• [/] Right Wing: Initial Install Fuel Tank
• [/] Right Wing: Install Landing/Taxi Light
• Remove extra wire going to rear cabin area

12, Monday

• Clean up fuel cut-off cutout
• Install fuel cut-off switch
• Right Wing: Fit wing-tips
• [/] Right Wing: Initial Install Fuel Tank

11, Sunday

• Double check that C75C2-8 is installed in control stick (a little play in aileron). It was installed, play is not much, just wanted to double check
• Right Wing: Cut out Landing/Taxi Light hole
• [/] Right Wing: Fit wing-tips
• Right Wing: Rivet (all but fuel tank cover)
• Cut/File out fuel cut-off switch stops

10, Saturday

• Purchase return line fuel hose
• Purchase hose clamps for Supply & Return fuel lines
• Clean inside of fuel tanks (get any metal shavings out)
• Clean shop
• Tank Sender Unit – Install (Right)
• Tank Sender Unit – Install (Left)
• Finish Brakes
• Right Wing: Run return fuel line

9, Friday

• Tank Sender Units – Cut into tank
• Tank Sender Units – Check wiring
• Pitot tube switch/power (cabin)

8, Thursday

• Install rudder support bumper
• Elevator trim power
• GAD 27 Elevator Trim Outputs to rear cabin area for Elevator Servo
• Finalize GAD 27 Connectors
• Finalize GEA 24 Connectors
• Nav/Strobe Light Power
• Put plate on transponder connector
• Anchor GNX Coax Cable free of anything that will cut it

7, Wednesday

• Order 20 AMP breaker
• Order 12 AWG wire for pitot tube
• Wire Boost Pump Switch to GAD 27 for Indicator
• Install relay connectors on fuel pumps
• Install relay connector on start switch
• Wire Pitot Heat Switch to GAD 27 for Indicator

5, Monday

• Order 5606 Hydraulic Fluid
• Order 2216 A/B Scotch Weld epoxy for brake line protection on gear leg
• Design a 3D printed bumper for front rudder support channel, center, to make sure it does not cut wiring
• Move CO detector power to Engine Bus
• Mount strobes in wingtips
• Hang new LED shop light

3, Saturday

• Finalize/cotter-key aileron bell crank
• Rivet throttle cable bracket (engine side)
• Mount heat muff
• Install brake calipers
• [/] Plumb brakes (pedals done, right caliper connected)
• Organize wires coming from cabin area
• [/] Finish cabin gas supply (fuel cut-off and line from switch to pump still outstanding)
• Grease wheel bearings

2, Friday

• Run power wiring for AP servos
• Flip wing onto bottom to enable fuel tank work
• Wire PWR 2 on GEA
• Make a 3D bumper for front panel wire protection: 63x20x158mm
• Trim Air Temp Probe wires

1, April, Thursday

• Wire elevator trim sensor cable to GEA
• Wire fuel sender cables to GEA
• Wire secondary power to GDU

March

31, Wednesday

• Trim center console sides to fit conduit
• Purchase piano wire for flap sensor install
• Temporarily Mount Flap Trim Position Sensor
• Temporarily calibrate Flap Trim Position Sensor
• Wire Landing/Recon switch to GAD 27
• Wire Taxi switch to GAD 27
• Wire Landing Light power
• Wire Taxi Light power
• Wire landing/taxi light switch to GAD 27
• Wire Motor Disconnect to GAD 27

30, Tuesday

• Anchor rear wire conduits
• Anchor front wire conduits
• Finalize GTR 200 Connectors
• Test noise from Transponder, It is coming out of the headset as well, removed shore power and speaker, still noise. Only while ADS-B is on.
• Clean up shop
• Install battery in ELT control head
• Wire Flap Trim Position Sensor
• Install center console floor L-angles

29, Monday

• Finalize ELT Wiring
• Test that ELT is getting GPS signal
• Finish 4th Flaperon

28, Sunday

• Mount ELT Speaker Unit
• Work on Fuel System (Cabin)

27, Saturday

• Mount ELT Control Head
• Rivet rear control tube support
• Install rudder cable bushings in rear control tube support

26, Friday

• Mount ELT
• Connect ELT 232 to GDU 460
• Pilot Control Stick Grip
• Co-pilot Control Stick Grip
• Wire USB Port
• Configure G3X for control stick Freq Swap

25, Thursday

• Decide what additional button on control stick grips should do (COM FREQ SWAP)
• Finalize Audio Panel Connectors
• Finalize GAD 29 Connectors
• Finalize GMC 507 Connector
• Finalize GDU 460 Connectors
• Finalize engine choice with Bob Barrows
• Run wires for Pilot and Co-pilot Control Stick Grips

24, Wednesday

• Fix alert audio from GDU to GMA
• Fix GNX 375 -> GDU 460 communication
• Work on 4th Flaperon
• Flap motor wiring

23, Tuesday

• Finish pilot side door frame
• Work with Garmin on the G3X reporting “ADS-B Pressure Altitude Invalid”
• PTT to Audio Panel
• Reconnect headset jacks to Audio Panel
• Reconnect power to headset jacks
• Reconnect MIC input to GTR 200
• Wire CO detector
• Test GTR 200 w/remote com radio
• Talk with Bob Barrows about an engine

22, Monday

• Mount Co-pilot stick grip
• Work on pilot side door frame (lower)
• Mount filtering capacitor

21, Sunday

• Add rivets to G3X
• Mount fuel switch
• Mount pilot side gascolator
• Mount co-pilot side gascolator
• Install heat muff
• Determine Fuel Line Routing

20, Saturday

• Finish Avionics Wiring: Clean up J4601 (GDU)
• Finish Avionics Wiring: Finalize J7001 (GMC)
• Finish Avionics Wiring: Finalize NAV 2000
• Secure Oil/Air Separator
• Build 3rd flaperon

19, Friday

• Finish Avionics Wiring: Debug GNX 375/G3X ADSB Pressure Altitude: Invalid
• Swap annunciator lights
• Work on Pilot Door Frame (Upper)
• Determine what other avionics need to be wired

18, Thursday

• Finish Avionics Wiring: Finalize J242 (GEA)
• Finish Avionics Wiring: Finalize J4601 (GDU)
• Finish Baggage Area: Rivet inner seat belt supports to gear channel
• Finish Avionics Wiring: Run ELT RS-232 (GDU->ELT)
• Finish Cabin Area: Co-Pilot Outside Seatbelt

17, Wednesday

• Finish Avionics Wiring: Fix wiring for items coming down through rudder cables
• Finish Passenger Door Frame (Upper/Lower)
• Finish Avionics Wiring: Wire AHRS RS-232 backup communications path
• Passenger door striker plates

16, Tuesday

• Partial: Finish Avionics Wiring: Reroute wires conflicting with rudder cables
• Passenger Door Frame (Upper/Lower)

15, Monday

• Swap PFD to Light Reference Bus #1
• Configure lighting
• Finish Panel: Move TO/GO Button

14, Sunday

• Finish Firewall Forward: Mount pilot heat butterfly valve on firewall
• Finish Firewall Forward: Mount co-pilot heat butterfly valve on firewall
• Finish Firewall Forward: Connect pilot heat butterfly valve to control
• Finish Firewall Forward: Connect co-pilot heat butterfly valve to control
• Finish Top Fuselage: Drill and Rivet L-angle support for Com Antenna

13, Saturday

• Loosely run rudder cables
• Finish Top Fuselage: Double check rear cage clearance with rear spar attachments
• Finish Top Fuselage: Run rudder cables with some temporary tension to determine if they conflict with magnetometer
• Finish Top Fuselage: Rivet magnetometer
• Finish Top Fuselage: Any holes in roof we shouldn’t rivet? If so, mark
• Finish Avionics Wiring: Rivet pilot side radio rack support to firewall
• Finish Avionics Wiring: Design and print center wire management bracket
• Finish Top Fuselage: Rivet roof

12, Friday

• Verify G3X annunciator for Check Engine:
• —> Turn on ECU once G3X is turned on. Does the Caution light illuminate?
• —> Unplug a sensor on the engine, does the caution light illuminate?
• Finish Panel: Mount Cabin Heat Control
• Finish Panel: Mount Defrost Control
• Finish Avionics Wiring: Secure bus bars behind co-pilot panel
• Finish Avionics Wiring: Install proper CANBUS connector for ECU
• Finish Top Fuselage: Run wire for elevator trim
• Finish Top Fuselage: Sand down AHRS support bracket

11, Thursday

• First Engine Run: Determine issue with magneto switch not shutting off Ignition 1 or 2 when switch to Left/Right settings. When switch to OFF, both ignitions were turned off. Conclusion: White wire was ran as GROUND but really it is Ignition 1, and WHITE/BLUE is ground. Switch was wired incorrectly. Fixed.
• First Engine Run: Tighten oil lines from thermostat to cooler. Tightened, but they were pretty tight already.
• First Engine Run: CHT #4 was not reporting during first engine run
• First Engine Run: Call and talk to Robert about fuel pressure bleeding off after pump ceases to run. Conclusion: Robert does not think there is any issue.
• Increase the wire size for the ESS wiring from master bus to breaker and switch
• Re-route firewall block harness wires

10, Wednesday

• Buy 5 gallon fuel tank
• Buy 5 gallons of 93 octane fuel
• Buy 3-ring flexible binder
• Buy case of AeroShell 15W50 oil from Skypark
• Add 2 additional rivets to the Fuel Pump Mount Rack
• Spark plug sanity check
• Battery properly charged
• Create test plan
• Create check list for engine run
• Check fuel system fittings
• Check for oil leaks
• Ensure all electrical connectors are secured
• [/] Secure wires firewall forward
• Attach ground ignition coils
• Configure prop correctly
• Create temporary hook for keys to make keys visible
• Cleco instrument cover
• Find suitable run-up area, and clean area of anything the prop may pickup
• Review test document with named crew
• Print test document
• Secure aircraft
• Ensure no loose items:
• —> In FWF
• —> In Aircraft
• —> Around Aircraft
• Drop fuel line to fuel tank
• Double check oil before start
• Start engine

9, Tuesday

• Rivet co-pilot brakes
• Add 2 quarts of oil
• Tighten fuel delivery system
• Oil/Air Separator
• Rivet/bolt firewall
• Applying fire seal
• Zip tie fiberglass sleeves over CHT/EGT probes
• Add boots to places where positive battery current flows
• Check for oil leaks
• Attach GNX 375 backplate
• Wire output from regulator
• Temporarily Protect wires going through firewall

8, Monday

• Proper propeller mounting – Initial pitch
• Design/print brake line fairings
• Co-pilot brakes
• Ignition Wiring
• Starter Wiring
• Add 1 quart of oil

7, Sunday

• Fuel Pump Wiring
• Mount air temp probe