Starter problem.

This weekend I finally completed the test flying. Sunday I completed all the paperwork and Monday it was posted to the PFA. Now all I have to do is wait........

The alternator has been fixed for a few weeks but the weather has stopped all test flying until this weekend. First flight was just 30mins to test the new alternator is working and set-up some more functionallity on the Dynon (D100). Second flight was the big two hr test flight and everthing went like clockwork. After downloading the engine data no problems showed up.

A really good day at the hanger today. Michael from Cambrai Covers came down to measure up for a travel cover and a future set of full covers. Late afternoon Alan came to do my weight and balance. I am pleased with the W&B figures. Miles also comes by and completes the final inspection..

Finally finished priming the cowl. Refitted this evening and brackets for wheel spats!

The last week of evenings I have been working on the cowls. I need to get some primer on them before the RV is flown to avoid oil getting into the fiberglass. As this will cause problems when they are painted.

INSPECTION Day - Miles my inspector came to check the RV over. Now I have a few things to sort out!!

Saturday at the hanger, fitted lower rudder cover - now with strobe lamp. Fitted the seal around the airbox inlet - to lower cowl. Also fitted lower cowl to baffle floor seal.

Mark the spark came and helped me in the hanger on Friday. We fitted the new control panel and refitted all the egine controls. We then spent a lot of time trying to bleed the brakes. Sunday Finally it came time..... TO START THE ENGINE ...... Jo & I moved the RV out of the hanger. The engine started first time easily and ran for a short while - it stopped and I realised I had selected the tank that I had drained!! So I took this chance to check the engine for leaks. I had one on the oil cooler, the joint was loose so I tightened it and restarted the engine - with some fuel this time! The engine ran well and I checked the Advanced Engine monitor settings. I stopped the engine, climbed out and was greated by an excited Jo leaping around excited about how well it had gone.

Saturday and Sunday at the hanger. Started by fitting the wing tips I had been working on during the week. I then had to empty the fuel tanks - I had filled them calibrating the fuel guages and forgot I need them to be empty for the weight and balance to be performed.Fitted rudder and elevators, HS end caps and VS top cap. I also discovered a fuel leak on the right wing tank. The fuel sender was leaking, so had to reseal it. Run update on Dynon D100. Fitted and wired elevator electric trim. Connected and adjusted the elevator control, and discovered the control stick hits the throttle control. Fitted wing to fuse cover on left side, didn't fit right side as I need to check the tank is not leaking. Riveted the internal spar fuse brace.

At the hanger early Saturday morning and worked all day then back home to the workshop to complete a few jobs on the bench.

The BIG move, I have moved the RV to the hanger and fitted the wings.

Removed the engine baffles and completed a few jobs on them - nutplates for ignition lead grommets & cut blast tube holes for mag's and alternator.

Started to rivet top skin into place - this is the last skin to be fitted! Jo is going to help with the riveting as it's not possible for me to do it on my own. Sealed fuel tanks and fitted the fuel float sender - instead of using proseal I used Stag Wellseal, this will not dry hard and will enable the covers to be removed for inspection if necessary.

A few odd jobs this eveing. Prepared the fuel tank senders ready for fitting. Put some paint on the canopy to help see how smooth I had finished the resin work. Fitted tank brace to fuse and riveted Gretz mount into wing.

I had originally decided to install the pitot as in the Vans manual. However after getting the Dynon D100 EFIS I decided to add the AOA (Angle of Attack) functionallity. This necessitated me installing the Dynon pitot with the Gretz mount. I thought it was going to take longer as I had the skin already installed. I completed most of the installation in one evening.

Worked on the cowl air intake today. The intake needs to be made level with the inner part of the cowl - just above the intake. This is to allow the air filter box to fit better. I have noticed some builders have not extented the intake, I almost didn't as I was able to make the air box fit. But decided today to do the extension as per plans.

The connectors I have been waiting to arrive to connect the flap indicator (and warning lamps) arrived today. So I was able to complete the flap motor with indicator installation. Also wired in the starter warning lamp and the backup alternator warning lamp. As I was inside the cocpit I decided it was time to complete the aileron trim installation, and connect the control stick together.

Wired the flap motor and fitted the Ray Allen flap position sensor - wired to the Advanced AF-2500.

Painted instrument panel last night, so was excited to start work on it tonight - getting the instruments fitted. Then I remembered I needed to fit the map box. I had intended to rivet the box in place then apply a second coat on the panel. However after riveting the box in place I am unsure about repainting, what do you think, take a look at the last pictures in this page and tell me.

Just a short day in the workshop today. I had some visitors - RV8 builder David and his wife. Then we went to the Popham RV fly-in. When I got back I finished fitting the ignition leads and (primer) painted the instrument panel.

Continued working on the canopy perspex to frame. I am using West Systems Epoxy with microlite to fill the front.

Fitted rear canopy catches. I had fitted them before but I cound after painting there was a problem - just the layer of paint caused them to catch and jam the canopy! I became suck inside for quite a while. I finally managed to free myself just as Jo arrived to see where I had got to - not come in for dinner.

Short day (Bank Holiday Monday) in the workshop. Tested all the electrics, radio & intercom. Also tested digital video recorder - Jo will be able to view films while flying!.

Busy weekend but I did manage to cut the heater and brake control cables to length.

Back to the wiring, fitted the EGT wires. Fitted the engine ground. Wired in 12v power pointo to both P1 & P2 positions to power noise cancelling headsets. Tidied wiring and fitted more P clips. I have also decided to fit a second backup alternator - B&C SD-8.

Just a quick hour in the workshop as I have visitors. Checking the cowl alignment and fitted eye ball grommets for the throttle, mixture and alt air controls.

Bonded hinge to upper and lower cowl. Used West System Epoxy Resin to bond the hinge to the cowl and riveted into place. Also modified the front baffles for the upper cowl inlet ducts.

A whole day in the workshop, worked on the baffles. Completed each corner and started to rivet together.

Baffle work around the oil cooler, riveted the parts together.

Not much work on the project this weekend. I had to collect my Cessna from the engineers on Saturday. However bad weather cause me to have to land at RAF Halton (the weather was still bad on Sunday). Somework on the baffles and riveted one cowl hinge on Sunday afternoon.

Still working on baffles. Front baffle floors - completed both sides. Started on front baffle behind flywheel..

Now I have the cowls fitted I am fitting the baffles - a tricky job to get correct.

Drove to Portsmouth this evening to get some West Systems epoxy for the cowl and canopy - I will be adding a page with what quantites of the West System you require..

Cut & fitted lower cowl side fixings, and trimmed around the front this evening. Have marked cut between upper & lower cowl ready for tomorrow evening.

Started fitting top cowl to the fuse today - Sunday. Pleased with progress went quicker and better than I expected.

BIG DAY. The Propeller arrived from Vans today, with Jo's help I had it fitted by the evening.

Decided to box in the audio connections on the PAX side. I placed them to the side rather than under the panel to keep the wires to the side. The headset connections could have been placed in the rear. But I wanted to keep the cable runs as short as possible, and if the pilot position has a problem it's easy to connect to the PAX position.

Fuse interior.

First fitting of the centre cabin cover and fuel tap housing.

Even more wiring this weekend, but I think I have the bulk of it done now. I have the wiring for the elevator and aileron trim controls and display's into the Advanced analogue unit. Saturday afternoon, friend and fellow RV builder Jerry came over to see how I was getting on. I was really usfull as some areas I was unsure of the best position to place things. So it was worth asking another builder - and somebody who has flown his RV for more than four years.

Spent this week working on the wiring.

A really big day today - Sunday. I spent nearly all day working on the intercom wiring, I have it all connected now - apart from feed to and from radio. The big part of today is - I applied the first power to the RV testing the intercom.

Finished remaking the instrument panel. Continued this week working on the instrument panel adding the P2 trim switch and heater control. I have run a lot of the wiring now it's time to start connecting things up. Spent most of this week working on the wiring - Radio, transponder and some work on the Advanced Engine Monitor (manifold, fuel tanks & RPM sensors). Spent all my evenings this week working on the wiring.

I had already fitted most of the baffle kit - to check it was compatible with the Superior engine. Decided it was time to progress the fitting, I can't do it all as I need the cowls fitted to govern the angles of the air inlet. I have been able to cut most of the parts. While working on the engine I decided to try the alternator belt. I tried three different sizes and still don't have one fitting as I would like. As my shipment arrived from Vans I fitted the new length throttle and Mixture control.

Mixed bag over this week, still disappointed with myself for messing up the instrument panel. I have fitted the manifold presure sensor on the firewall. The RPM pickup to the magneto, and started planning the fitting of the trim wiring and governor.

Jade have delivered the new fuel servo. This reverses the mixture control so the lever can operate from the top. This enables it to clear the airbox. Unfortunatly the mixture control cable is too short and the throttle control is slightly taught so I may get a longer throttle also.

Fitted the radio aerial.

Fitting the intercom/radio jacks. I decided to modify the air vent mount - extend it down to take the headset connections. Plus on the PAX side music input and a power connector.

My order from Vans arrived today, so I could finally fix the fuel line. Finally fitted the aileron trim servo, final fit strobe power pack.

In the workshop for the afternoon decided to build the mount for the Dynon EDC-D10A External Magnetic Sensor Probe. I have decided to mount it behind the baggage compartment. The Magnetic sensor must be mounted as closely aligned with the D100. It should be mounted with the long axis parallel to the wings, the electrical connector facing toward the front of the plane. The pitch, roll and yaw must be within a degree.

Connecting sensors to AF-2500. Fitting aerial leads for transponder and radio. Starting work on cowl - spinner, with the intention of fitting the spinner to align the cowl. BUT I discovered a problem with my plan.

Almost a full day in the workshop today - fitted wiring for starter, Nav, Strobe and Landing lights. Radio & transponder power. Flap switch & alternator. Started wiring in AF-2500 engine monitor.