Builder's Log
DateAssemblyInstructionPartDescriptionLinks
05/25/2013 Controls C01 C02-08 C01-01

C02-08 Rudder Pedal Pivot Block Assemblies.
I made the Rudder Pedal Pivot Blocks from phenolic.
I used the band saw to cut the blocks of phenolic to the proper size.
I used the drill press to drill one of the bolt holes through the blocks for each assembly.
I then placed each assembly under its attach angle. Using the actual attach ange as a template I the started the second hole for each assembly. I then finished drilling the second bolt hole using the drill press.
I bolted together each assembly and used the drill press to drill the 1in holes.
I used a half round file to file a chamfer the edge of the holes that are next to welds on the rudder pedals.

C01-01 Controls Installation.
I installed the C02-08 Pivot Blocks and the C02-09 Rudder Pedal Assemblies.

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10/26/2013 Controls C01 C04-05 C04-07

C04-07 Flap Handle.
Cut the bar stock to length using a hack saw. Used the arbor press to make the 25 degree bend per the plans.

C04-05 Flap Handle Assembly.
Drilled the holes and installed the bolts to attach the Flap Handle to the Flap Drive Tube.

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12/18/2013 Controls C01 C02-04

C02-04 Push Rod Assembly.
I started to work on the assembly. I removed the tape covering the threaded end of the push rod. I then realized that the control rod end bearings needed some work.
C01 detail K. I drilled the witness holes for the control rod end bearings. I also pressed the brass bushings that reduce the ID for the rod end bearings.

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12/19/2013 Controls C01 C02-04

C02-04 Push Rod Assembly.
I used a propane torch and a wire brush to clean off the powder coating. I used the drill press and cordless drill to drill and up drill the bolt hole at the end of the push rod. I applied white Lithium grease to the push rod. I slide the springs and slider on the push rod. I installed the bolt through the end cap and push rod.

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01/31/2014 Controls C01 C09-19 C09-20

C09 Center Controls Detail.
Attach Angle and Flap Support Angle.
Today I fabricated two parts that will be the center support for the flap drive tube. This is where the flap handle will attach to the drive tube. I also drilled the 1 inch hole through the phenolic block that will also support the drive tube.

Today was the first time since I moved to the hanger that I wasn't able to have the hanger door open all day.

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02/01/2014 Controls C01 C08 I used a propane torch and wire brush to remove the powder coating on the flap drive tube where the center support block goes. I put the flap drive tube in the fuselage to start locating the center block and support angles.

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02/03/2014 Controls C01 C08 C09-17

C08 Center controls.
I located the positions for the support angles with the block attached to the flap drive tube. I drilled and up drilled all the holes for the support angles. I dimpled the three holes for the forward spar tunnel and support angle. I deburred all holes and installed the three ccc-42 rivets attaching the center support angle to the forward spar tunnel.
C09-17 Hinge halves.

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02/10/2014 Controls C01 C01

C01 Controls.
C02-03L&R Rudder Cable Adjusters.
I fabricated these two parts from 1.5 inch wide bar stock. I used the band saw to cut to size. I used the drill press to drill the holes. I used files and the scotch brite wheel to finish the size and shape.
C01 Controls - Rudder.
I started following the plan general instructions for the rudder. I removed the retaining clips for the fairleads so I could thread the rudder cables from the front to the back of the fuselage. I reassembled the fairleads. I attached the aft cable ends to the rudder drive horn.

L07 Hydrualic Brakes and Wheels.
The pucks seemed to be keeping the inside bearing from fully seating. So I tried using a hardware store washer as a spacer but that left a large gap between the disk and the pucks. I removed the pucks and then the bearing fully seats. So I have ordered some AN960-1216 light washers. These washers have a thicknes of .032. I think that one or two of theses should space every thing a proper distance. We shall see.

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03/04/2014 Controls C01 C01

C01 Controls.
Rudder Cables and Adjusters.
I followed the plans order for installing and rigging the rudder cables and adjusters. I also installed the rudder return springs. The springs need to be shortened and adjusted.

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03/05/2014 Controls C01 C01

C01 Controls.
Rudder Return Springs. Spent the day adjusting the springs.

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10/18/2014 Controls C01 C05

C05-01 Control Stick Assembly.
Used the arbor press to press the bushings into the C05-01 Control Stick Assembly.
I used a propane tourch and wire brush to heat and remove the powder coating on the C04-08 Horn Assembly where it goes into the bushings on the control stick assembly. I also used emery cloth to polish the area where the powder coating was removed.
I also wrapped some Emory cloth around some tubing to use to ream the bushing to get a proper fit.
I put the C04-03 Stick Grip and C04-08 Horn Assembly on the C05-01 Control Stick Assembly.
I drilled and up drilled to 1/4" size holes through the Stick Grip and Horn Assembly to bolt them in place on the Control stick Assembly.

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10/20/2014 Controls C01 C05

C05-01 Control Stick Assembly.
I greased the bushings for the Horn Assembly and Stick Grip.
Installed the AN 4 Bolts holding the Horn Assembly and Stick Grips on the Control Stick Assembly.
I located and drilled the hole for the C05-07 Link Rod.
I reamed the holes on the Link Rod Assembly so the the bushings would rotate in the holes.
I greased the bushings and installed the AN 3 bolts holding the Link Rod to the Control Stick Assembly.

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10/28/2014 Controls C01 C01

C01 Controls Installation.
Trimmed the stops on the C05-01 Control Stick Assembly so they would clear the landing gear attachment bolts.
Installed the C03-04 Stick to Idler pushrod.
Checked the placement of the SP7 Attitude Sensor. This was the reason I decided to install some of the controls now. To see where to place the sensor and wires etc.

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12/19/2014 Controls C01 C01

C01 Controls Installation.
Followed the general instructions for the elevator control system. Drilled the the three holes for the AN3-12A bolts holding the C03-05 Elevator Pushrod End Fitting to the C03-06 Elevator Pushrod.

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02/02/2015 Controls C01 C01

C01 Controls.
Trimmed the seat pan to allow full back movement of the stick assembly.

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02/10/2015 Controls C01 C09

C09 Center Controls Detail.
C09-12 Flap Detent Bracket. Started layout and fabrication.

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02/11/2015 Controls C01 C09

C09 Center Controls Detail.
C09-12 Flap Detent Bracket. Finished layout and fabrication.
C09-13 Brake Detent Bracket. Layed out and fabricated.
C09-02 Flap Handle. Reworked the C04-07 flap
handle to make the C09-02 flap handle. C09-05 Bushing. Made from bushing stock.

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02/12/2015 Controls C01 C09

C08 Center Controls Install.
Installed rivets to hold Center Flap Mount Bracket.

C09 Center Controls.
C09-01 Flap Handle Assembly.
Drilled holes and installed hardware to make the assembly.

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02/25/2015 Controls C01 C09

C08 Cneter Controls Install.
Located and drilled holes to attach flap detent bracket to spar tunnel.
C09 Center Controls.
Made new hinge pins for seat pan for attachment to the spar tunnel with the center controls.

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03/01/2015 Controls C01 C08

C08 Center Controls Install.
Finished Brake handle.
Worked on Flap Handle to get a better fit in the flap detent bracket.

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03/02/2015 Controls C01 C08

Trim System.
Installed Attach point for rear spring.
Drilled and installed conduit retainer for cable. Hydrualic brakes.
Installed two clamps to hold brake lines in place.

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03/03/2015 Controls C01 C08

Trim System.
Installed the Trim System.
Attached the rear spring and clamp. Ran the cable and cable conduit. Trimmed the conduit to length.
Attached the front spring. Made the cable link. Attached the cable to the front spring. Found the cable was rubbing on the flange by the seat belt attachment. Moved the hole for the cable conduit retainer to give clearence.
Finished intalling and adjusting the Trim Sytstem.

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03/04/2015 Controls C01 C08

Put the lower rear skin back on with clecos and bolts. Installed the transponder antena. Put the throtle and mixture cables back in place.

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05/30/2015 Controls C01 C01

Installed the Aileron push rods to connection to the bell crank in the wings.

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06/03/2015 Controls C01 C01

Installed the flap control rods and hardware.

Worked on engine baffles.

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11/03/2015 Controls C01

Fabricated the Flap Fairings. W01-02.

Worked on fabricating the rudder cable fairings. C01-04.

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11/04/2015 Controls C01

Worked on fabricating the rudder cable fairings. C01-04. Enlarged cut out in fuselage for right rudder cable for better clearance. Installed fuselage access covers. Worked on programing the Xtreme EFIS EMS settings.

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1/16/2016 Controls C01

Worked on installing cotter pins in controls.

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1/18/2016 Controls C01

Worked on Aileron hinges and push rod connections.

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1/19/2016 Controls C01

Worked on Aileron hinges and push rod connections.

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1/20/2016 Controls C01

Worked on installing cotter pins in controls.

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