|2003-06-01||Drilling Control Horn||Here is the way that I held the inboard rib to forward spar angle correct while drilling through the control horn. I used two elevator skins, one on top and one on the bottom. This leaves the control horn accessible for drilling.|
|2003-11-24||Wings Mounted||The wings are mounted and ready for the stressful drilling of the incidence angle.|
|2003-12-02||Pictures||Pictures of empennage attached.|
|2003-12-02||Dad is Helping||Here is my Dad helping out with the exhaust.
|2004-02-18||Engine is Hung||Here is a picture of the engine hung on the engine mount.|
|2004-03-08||Early Firewall Forward Picture||Early in the process of integrating all the firewall forward \"stuff\".|
|2004-05-23||Drill Hinges||Drilled and fit the sheet metal parts between the firewall gear mount and the lower cowling. Match drilled to the gear mount and painted the parts.
Cut the hinges for the joint between the upper and lower cowl halves. Drilled the hinges and clamped in place on the lower cowl. Match drilled the cowl through the holes drilled in the hinges on right and left side.
Now I have to try to figure out how to drill the hinges to the upper cowl . The instructions ar no help.
|2004-06-13||Prop Arrived||Here is a picture of the prop mounted temporarily for a picture.|
|2004-07-11||Air Seal Fabric||Installed airseal fabric around front bulkhead.|
|2004-09-26||Panel Powered Up||Here is the panel all powered up except for the autopilot.|
|2004-11-19||Wiring Clean Up||Started bundling wires behind the panel. What a mess.
Installed new 10 position fuse block for E-Bus
|2004-11-20||Spiral Wrap||Sprial wrapped wire bundles in the mid fuselage tunnel. Secured bundles with adel clamps.|
|2004-11-20||Bundling Wires||Started to bundle the wires in the fuselage tunnel.|
|2004-11-26||Re-Installed Controls in Cabin||Installed the aileron trim servo with the 9 pin connector and secured to the seat rib.
Torqued the control fasteners which removed most of the play from the control stick.
|2004-11-26||ELT Installation||Installed ELT and antenna.
Ran cable from stobe power supply to right wing root.
More work on EDC-10 Installation.
|2004-11-28||Copilot Stick||Here is the copilots stick installed with the PTT switch on the top. The flap motor and control box are inside this enclosure between the pilot and copilot.|
|2004-12-12||Elevator||Here is the elevator autopilot servo mounted along with the strobe power supply.|
|2004-12-19||Wing Plumbing||Here is a picture of the roll servo installation.
I still have to wire the D-Sub 9-pin connector to connect the wire to the servo.
The plastic bushings should work fine for the plumbing.
I also started installing the right wing tip.
|2005-01-01||Wing Tip||Match drilled wing tips and installed tip ribs. Also installed nav lights in the tips.|
|2005-01-02||Installed Right Wing||Soldered roll servo d-sub connector.
Installed right wing in preparation for installation of landing light.
I will also finish the plumbing in the right wing before removing it and installing the left wing.
|2005-01-10||Landing Light||I installed the landing light today. The instructions said a few hours, more like eight.
Straight forward but time consuming.
|2005-01-11||Right Wing||Installed right wing tip with lights. Trimmed lens.|
|2005-01-11||QB Tanks||Here are some pictures of the QB tanks.|
|2005-01-13||Pitot Mast||The pitot mast is not wide enough for the RV-9A. Specifically the welded on plate that overlaps the spar.
I added two more rivet holes between the existing holes and trimmed the plate to clear the existing rivet holes.
The first picture shows where the existing holes are on the plate. Used the existing holes as a template. No edge margin.
The second picture shows the designed layout.
The third picture shows the mast installed with the new rivet holes between the existing rivet holes.
|2005-01-13||Tank Removed.||Here are some pictures with the right tank removed.|
|2005-01-13||Left Tip||Installed left wing tip lens.|
|2005-01-14||Left Tip||Installed the nut plates and the VOR antenna.|
|2005-01-16||Taxi Light||Installed the taxi light in the left wing.
Still have to install nut plates and dimple the wing skin.
|2005-01-22||Taxi Light||Installed taxi light in left wing.
Installed fuel sender in left wing.
|2005-01-23||Right Tip||Match drilled, CS and installed nut plates in right tip.
Bonded in tip ribs on both wing tips.
|2005-02-06||Canopy Frame Shape and Position||What a pain!!!
Here are a few pictures of the canopy frame and the jig I used to help control the shape.
|2005-02-11||Canopy Frame Bending||Ugh. Pain in the A....|
|2005-02-12||Plexiglass Trimming||Messy. Cut plexi into two pieces. Trimmed|
|2005-02-13||Windsreen Trimming||Trimmed to near final shape. Fits pretty good.|
|2005-02-18||Canopy Spacers||Added spacers between canopy and frame to allow for bond line sufficient for CTE differences|
|2005-02-19||Windscreen and Canopy Side Skirts||Fit windscreen and started on the side skirts.|
|2005-02-20||Side Skirts and F-7112 skin||Finished match drilling side skirts and then started riveting the upper fuse skin.|
|2005-02-21||Test Fit of Seats||Put the seats in and sat in them for a while. Pretty comfortable.|
|2005-03-06||Baffles and Oil Cooler||Mounted oil cooler. It may be too close to the engine mount, I will ask around. I mounted the oil cooler as high and outboard as possible.|
|2005-03-18||C-791 Drilled||Vicki and I drilled the C-791 to the side skirts. I thought that I could pull in the side skirts more during this process. Not!|
|2005-03-20||Aft Skirt Fit||I started to install the left aft skirt today. The fit is so so. It gaps at a couple places as you can see in the pictures. I still have the canopy propped open slightly so maybe it will fit better when I close it fully.|
|2005-03-26||Aft Skirts||Fitted, trimmed and drilled aft canopy skirts. The fit is pretty good, better than I expected.|
|2005-03-27||Wire Routing Clean Up||Still trying to get all those wires in nice neat bundles. What a headache. I am not a good electrician.|
|2005-03-27||Peeled Coating||Peeled off the protective coating. Looks good. Waiting for good weather to paint the aft skirts.|
|2005-04-24||FF Stuff||Installed Oil Cooler and...|
|2005-04-29||Temporary Install of Interior Kit||the interior kit from Classic Aero Arrived today and I had to put it in to see what it looked like.
The seats rub the side panels so I will have to trim and smooth the seats backs so they don't tear up the sidewalls.
|2005-04-30||Baffles Again||Removed the baffles to add doubler plates where the safety wire attaches on the lower baffles.
I did not like the safety wire being on a sharp edge so I bent up some hinge pin rod to make the safety wire wrap around a nice round object. I drilled a hole adjacent to insert the bent portion of the rod to keep it from moving.
|2005-05-01||Riveted||Riveted two of the baffle plates together and installed the prop.
Started working on the template to cut the spinner for the prop.
|2005-05-15||Spinner Installed||Most of today was spent installing the spinner. I started onthe air inlet but wanted to install the spinner so I will know how easy it is to get the lower cowl on and off. The air inlet has to be trimmed to allow the lower cowling to be removed, I want the spinner in place before trimming.
|2005-05-29||Air Box||Here are some pictures of the air box with filter bypass door, carb heat muff connection and gap seal.|
|2005-05-30||Primer System Install||Her is the primer system all plumbed. I think I might change the attachment near the "T" for better support.|
|2005-06-01||Aft Skirts||Here are the aft skirts after installation. I bonded them with the SikaFlex 256. They are riveted to the side skirts and I fabricated a stainless steel strap to attach the canopy and the aft skirts to the canopy frame.|
|2005-06-02||Hinge Pin Restraint and Canopy Latch||Here is a picture of the hinge piece I attache to the firewall to hold the ends of the hinge pins holding the upper cowl to the firewall.
A picture of the canopy latch after I trimmed it to the correct length.
|2005-06-08||Carb Heat, Throttle and Mixture||Installed carb heat, throttle and mixture control cables.|
|2005-06-26||Riveted forward deck.||What a pain, but it is done.|
|2005-07-02||Windscreen||Hera are a few shots of the windscreen after bonding and screwing to the fuselage.|
|2005-07-04||Tip Installation||The empennage tips are nearly finished. One more fiberglass reinforcement ply and the HS and VS tips can be installed.|
|2005-07-23||Windscreen Fairing||It is finally done. I spent three weeks on this fiberglass fairing. Ugh. It came out very nice. Just a little filler before paint.|
|2005-07-24||Lower Outboard Skins||The lower outboard wing skins are riveted! I have a few scars on my arms but it is done.|
|2005-07-31||Installed the Interior Kit||Attached all the velcro used to hold the interior components in place. I have to make one slight modification to the baggage compartment side panels due to an interference with the canopy rear hold down block.|
|2005-09-18||First Flight Pictures||Here a couple of shots of the airplane the RV Grin.|