Wired the radio stack

Made my first CAN Bus daisy chain termination for the GTR 200B com radio.

 

Finished wiring the COM radio connector.

 

Terminated the antenna cables with BNC connectors for the transponder and com radio and a TNC connector for the GPS.

 

Made up the connector for the GMC 507 autopilot control. Pretty simple… Power, Ground and CAN bus.

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Installed the com radio tray and the transponder and GPS trays that I had pre-wired. I routed and tied all the wires.

 

Today’s Time (hours): 8.0
Finish Kit (hours): 120.0
Total Time (hours): 850.0

 

Progress continues on wiring

I’ve neglected to post over the past week. Been a busy week at work. I have made some good progress though.

I vinyl-wrapped the fuse block panel and screwed the fuse block into it. I made a bus bar from a strip of copper to tie together the upper and lower buses of the fuse block.

 

I drilled some system holes through the left seat ribs, installed snap bushings, and ran the pitot and AOA lines from the wing root to the panel.

 

Drilled a couple of system holes in the lower sub-panel. Routed the the wires for the battery backup. Terminated the grounds for the the IBBS and the IBBS master switch.

 

Made up the connectors for the GTX 45R transponder and the GTN 625 GPS. I also started on the GTR 200B COM radio but didn’t get a picture.

 

Today’s Time (hours): 6.0
Finish Kit (hours): 112.0
Total Time (hours): 842.0

 

Began work on Fuel System (Section 31)

Took a break from riveting the the fuselage together. Jared’s lending me his engine-stand-fuselage-rotisserie. So I’ll wait until he drops by next weekend to finish the riveting. It’ll be a lot easier if we can roll the fuselage on its side.

So… Got started on the fuel system tonight. Picked and inspected all the parts.

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Separated the fuel line brackets and riveted to the cover ribs.

 

 

Disassembled the fuel selector valve. Oriented the fittings per the plans but couldn’t screw them in because I didn’t have the Loctite 648 that the instructions called out. Ordered some from Amazon. I riveted nut plates to the flanges of the valve. Finally I machine countersunk the screw holes in the face plate.

 

 

Crimped the connectors on the leads from the fuel pump. Added thread sealant to the fuel filter fitting and screwed it into the pump. Mounted the pump and filter into the into the fuselage.

 

 

Attached the AN elbows to the firewall and fuselage sides.

 

 

 

Today’s Time (hours): 3.0
Fuselage Time (hours): 136.0
Total Time (hours): 590.5

Completed left wingtip–Almost

All the things I did to the right wing yesterday, I did to the left wing today.

 

 

Thought I was finally at th end of the wings… but ran into another snag. When I was countersinking the screw holes in the tip, I hit a thin spot in the fiberglass and the countersink caught and made a giant hole. So I made a fiberglass patch. I’ll fill in the other side with some micro once the patch sets up. Then I can install the final nut plate and be done with the wings!

 

 

Traveling this week. So I will begin work on the fuselage next weekend.

Today’s Time (hours): 5.0
Wing Time (hours): 298.0
Total Time (hours): 450.0

 

Completed Right Wingtip

Laid out the cut the left and right wing tips. I made over-ran on of the cuts by an inch or so on the left wing. So I did a little patch and fill with some fiberglass and micro and set it aside to cure. Then continued work on the right wingtip.

 

Cut and installed the nav light lens.

 

Installed the nav/strobe light. Used the template from the plans to drill the wingtip. Terminated the wires with Molex .062 pins. Unfortunately Vans provided a 4-pin molex housing instead of the 5-pin one that matches the wiring harness in the wing. <sigh> Now I get to pay $10 in shipping for two $1 moles housings. Mounted the bracket and installed the light. Tested it out with a 9-volt. That sucker is bright!

 

Fit the wingtip to the wing and set it in place with a ratchet strap. Match drilled the holes from the wing skins to the wingtip. Final drilled and dimpled the holes in the wing for #6 screws. Final drilled the screw holes in the wing tip and then used a nut plate, a screw, and a cleco as a drill jig to drill the nut plate attach holes. Machine countersunk the screw and rivet holes and riveted the nut plates in place.

 

Fit the wing tip rib to the wingtip. Laid out and match drilled rivet holes. Riveted the rib in place.

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Bam! Right wingtip done.

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Today’s Time (hours): 8.0
Wing Time (hours): 293.0
Total Time (hours): 445.0

 

Bottom Skins Complete

Received the new quick-disconnect terminals and replaced the bad ones. Then I final-installed the pitot tube into the wing and hooked up the plumbing and the electrical. Had to uninstall and reinstall the aileron push tube so that I could get my hands in there.

 

Reinstalled and torqued the aileron push tube in the right wing and installed the aileron trim. Getting those springs on is tricky. I also took the time to bend the actuator arm aft a bit. I just saw a picture on VAF where someone’s springs had almost worn completely through the push tube. Plenty of clearance now. No rubbing.

 

Riveted the nut plates for the right wing inboard fairings and inspections plates.

 

Almost done! Just the wingtips left to do.

 

Today’s Time (hours): 2.0
Wing Time (hours): 285.0
Total Time (hours): 437.0

 

Fitted the aileron trim and inboard bottom skins

I finished inventorying and stowing parts from the fuselage kit and avionics.

Crimped the pins onto the aileron trim wires, added a heat shrink tube, and inserted them into the molex connector.

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I centered the set the aileron trim using a 9-volt battery to drive the servo. I set the  assembly in place on the wing and set the aileron to the neutral position. Then I marked the point where the aileron trim arm rested over the  push tube. I remove the push tube and located the tabs 6 inches either side of the center mark. I match drilled and blind riveted them to the push tube. I attached the springs to the tabs.

 

I clecoed the inboard bottom skins in place on the wings. Ready to rivet.

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Today’s Time (hours): 4.0
Wing Time (hours): 264.0
Total Time (hours): 416.0