Found some more nut plates and added them to the trim servo access hatch.

Made a fork and then riveted in a small bracket to help keep the fire extinguisher from coming loose.

Drilled and deburred wing root covers to final A4 size.

Neutralized and set flaperon controls. Re-set aileron bump stops. Setting the ailerons is tricky, made worse when alone. First it is hard to determine the true up-right neutral position of the stick. Then you have to verify the lower torque tube bellcrank is in alignment ( not that much could be done about it now... ).

Finally it is a long slow process of measuring reference lines from the wing for gap distance. One trick I realized was to measure the angle between the rivet line for the push rod covers against the extrusion the connects the flaperon to the pushrod.

Luckily I had left the inboard pushrods coming from the torque tube long. This gave me more choices on setting the amount of reflex or deployment for a flaps up position.

The pushrods and jam-nuts are not flight ready.

The aileron bump stops are not the best designed items. Their placement is some what arbitrary and can be hard to align properly.

Using the darkness I verified the landing lights are aimed correctly.

On Tuesday the final securing of wires will be done. The steering push-rods will also get set.

Punch List:
FINISH PROCEDURES\MANUAL
Shorten steering pushrods, install plates to lengthen rudder cable.
Fuel flow test
Final securing of wires aft of seats in luggage
More cotter pins & safety wire ( flaperon pushrods & steering pushrods )
Safety wire turnbuckles on rudder cables.

Install wing root fairings ( post inspection )

fabricate, install streamlined strut covers. ( post first-flight )
VGs on elevator ( after initial test flights )

Fabricated wire supports in access hatch. Created addition support for fire extinguisher.

Debugged transponder issue. I suspect it may have been caused by the GPS input on pin 2. Setting the Dynon to 29.92 matched the pressure altitude shown on the Garmin 327. Turning off the Dynon blanked the pressure altitude reading.

The manual indicates ( in very small print ) that NMEA inputs are not supported from the 396\496. Therefore I pulled the #2 pin to remove the input. This may have been a grounding issue caused by the GPS input or a software issue caused by the transponder attempting to decode bad input.

Found that taxing had loosened a bolt holding the passenger side nav light. Drilled out wing tip and tightened. Tips held by screws would be best, but may be impossible.

Punch List:
FINISH PROCEDURES\MANUAL
nuetralize aileron rods & control
Shorten steering pushrods, instal plates to lengthen rudder cable.
Final securing of wires aft of seats in luggage
More cotter pins & safety wire ( flaperon pushrods & steering pushrods )
Safety wire turnbuckles on rudder cables.

Install wing root fairings ( post inspection )

fabricate, install streamlined strut covers. ( post first-flight )
VGs on elevator ( after initial test flights )

Made a first attempt at transponder inspection. Bits were being adding on the discrete code while in the plane, but not on a bench. Not cause has been identified yet.

Added reinforcements to the radio stack. Tightened and flight readied all nut plates related to the radio stack.

Adjusted aim of landing lights.

Installed nutplates and cover for elevator trim motor.

Punch List:
Fabricate wire bundle supports for rear cargo area.
Have transponder tested by avionics shop
FINISH PROCEDURES\MANUAL
VGs on elevator
nuetralize aileron rods & control
Shorten steering pushrods, instal plates to lengthen rudder cable.
Final securing of wires aft of seats in luggage
More cotter pins & safety wire
Safety wire turnbuckles in "double wrap" style
fabricate, install streamlined strut covers. ( post first-flight )

Had a project visit and identified a few more minor changes.

Lost the elevator trim servo cover ( held on by clecos ) during a runup test.

Torqued more bolts to final, riveted flaperon covers into place. Touched up primer on a few steel parts.

Fixed tachometer reading on Dynon. Tied down more wire bundles.

Punch List:
Fabricate wire bundle supports for rear cargo area.
Fabricate new elevator servo cover.
Have transponder tested by avionics shop
FINISH PROCEDURES\MANUAL
VGs on elevator
nuetralize aileron rods & control
Shorten steering pushrods, instal plates to lengthen rudder cable.
Final securing of wires aft of seats in luggage
More cotter pins & safety wire
Safety wire turnbuckles in "double wrap" style
fabricate, install streamlined strut covers. ( post first-flight )

Tensioned elevator. Re-adjusted slack bungee, added nylon blocks where elevator cables could rub. Safety wired elevator turnbuckles. Removed elevator and adjusted bolts, installed & castelated elevator bolts.

Finalized rudder bolts.

Bolted battery into position.

Installed dataplate.

Greased all bushings, control bolts.

Aimed landing lights.

Punch List:
Tighten passenger door ( opened during run-up )
Have transponder tested by avionics shop
FINISH PROCEDURES\MANUAL
VGs on elevator
nuetralize aileron rods & control
Shorten steering pushrods, instal plates to lengthen rudder cable.
Final securing of wires after of seats in luggage
More cotter pins & safety wire
Safety wire turnbuckles in "double wrap" style
fabricate, install streamlined strut covers. ( post first-flight )
Correct tach reading on Dynon, reconnect hobbs meter.

Re-weighed the plane.
Nose: 162lb, arm=670mm
Left main: 232, arm= = 690mm
Right main: 232, arm = 670mm

Added RTV seal & trim around fuel neck filler & wing skin. Tightened a few more bolts & added cotter pins to all but two steering & rudder nuts. Added fuel type markings.

Tightened bolts between steering push rods and nose strut along with jam nuts.

Found fuel senders were "double grounded" and pins were crossed. Fixed fuel sender wiring. Flushed fuel system and calibrated Dynon fuel sensors.

Bled brake lines.

Charged battery.

Started engine from fuel in wing tanks.

Taxied under own power across the airport. Started break-in procedure for Matco brakes. Verified steering and brakes.

Punch List:
FINISH PROCEDURES\MANUAL
Final placement of battery
Install EAB plaque
VGs on elevator
nuetralize aileron rods & control
Final securing of wires after of seats in luggage
More cotter pins & safety wire
Safety wire turnbuckles in "double wrap" style
fabricate, install streamlined strut covers. ( post first-flight )
Install steering boots
Install nylon strip in service hatch to protect against elevator cable rub
Remove elevator & grind down clearance of center hinge.
Correct tach reading on Dynon, reconnect hobbs meter.
Aim, secure landing lights

Finished transition training. Adjusted elevator tension bungee. Trimmed wingroot covers, ready for rivetting once fuel system is fully tested. Installed fire extinguisher. Added extra nutplates for cowling. Epoxied NACA inlet adapter for oilcooler. Fitted washers for bellcranks. Created steering boots.

Trimmed, primed and installed dorsal fins. Bunch of small stuff.

Punch List:
FINISH PROCEDURES\MANUAL
W&B
Final placement of battery ( pending W&B )
Engrave & install EAB plaque
Fuel Filler Marking for 10G 92MoGas\100LL w/TCP
Post registration in cabin
bleed brake lines
VGs on elevator
nuetralize aileron rods & control
Fuel tank calibration
Final securing of wires after of seats in luggage
More cotter pins & safety wire
Safety wire turnbuckles in "double wrap" style
Torque seal push rod jam nuts.
fabricate, install streamlined strut covers. ( post first-flight )
Install steering boots
Install nylon strip in service hatch to protect against elevator cable rub

Fabricated a replacement bellcrank spacer and installed it. Fabricated replacement jury strut. Disassembled flaperons and primed them. Riveted flaperon root pins. Greased flaperon bearings and reinstalled flaperons. Cleaned up wing root skins and ready them for final trim. Installed a stiffener underneath the dashboard trim, partially pulled the panel lights and re-installed them so to not tension the dashboard again.

Punch List:

Got a ton of stuff done this weekend:

Fabricated and installed the oil door, installed a few cotter pins, removed the elevator trim and modified the hinge to accept safety wire, installed the elevator tensioning bungee, re-installed the doors, fabricated access panels into the seat pans, installed the access panels and re-installed the seat pans.

Punch List:
FINISH TRANSITION TRAINING
FINISH PROCEDURES\MANUAL
install wingroot covers.
W&B
Final placement of battery ( pending W&B )
Engrave & install EAB plaque
Fuel Filler Marking for 10G 92MoGas\100LL w/TCP
Post registration in cabin
mark "EXPERIMENTAL" on entry way
bleed brake lines
VGs on elevator
nuetralize aileron rods & control
Fuel tank calibration
Final securing of wires after of seats in luggage
install first-aid kit and fire extinguisher
Washers for aileron bellcranks
Nose gear pushrod boots
Install dorsal fin
Two additional cowl fasteners
More cotter pins & safety wire
Safety wire turnbuckles in "double wrap" style
Torque seal push rod jam nuts.
fabricate, install streamlined strut covers. ( post first-flight )
finish priming bare surfaces.

Got a ton of stuff done this weekend:

Fabricated and installed the oil door, installed a few cotter pins, removed the elevator trim and modified the hinge to accept safety wire, installed the elevator tensioning bungee, re-installed the doors, fabricated access panels into the seat pans, installed the access panels and re-installed the seat pans.

Punch List:
FINISH TRANSITION TRAINING
FINISH PROCEDURES\MANUAL
install wingroot covers.
W&B
Final placement of battery ( pending W&B )
Engrave & install EAB plaque
bleed brake lines
VGs on elevator
Adjust control tension
nuetralize aileron rods & control
N-Number on panel
Fuel tank calibration
Re-fab spacer on passenger side aileron bellcrank
Re-fab diagonal pass side jury strut
Final securing of wires after of seats in luggage
install first-aid kit and fire extinguisher
Washers for aileron bellcranks
Grease on bellcranks
Nose gear pushrod boots
Install dorsal fin
Two additional cowl fasteners
More cotter pins & safety wire
fabricate, install streamlined strut covers.
finish priming bare surfaces.

The weekend was somewhat frozen and short on time at the hangar. The aileron stops are installed. I adjusted the flaperon and aileron pushrods to what may be a nuetral position, testing will tell for sure.

I fabricated the flaperon bungee rention system, but am having problems reaching underneath the seat to install the bungee cord.

The new landing gear leaf is in. Hopefully it and the brake lines can be installed in a few weeks. Following that only the jury struts and dorsal fin will remain for installation.

Latest work:

Skylight and windshield all installed and unwrapped.
Interior painted and ready. Only a few more wires need to be secured in the cabin
Controls re-installed with continuity restored. All lingering clearence issues fixed.
Rudder pulleys and flaperon mixed riveted down
Sealant & RTV installed to prevent leaks

Punch List:
W&B
Final placement of battery ( pending W&B )
Engrave & install EAB plaque
Install new Grove gear
Brake lines
Cotter pin on bungee pin & outer sleave to tighten
Fabricate top bungee retaining pin
Drill cotter pin holes for elevator bellcrank, elevator retainer and flaperons
VGs on elevator
Adjust control tension
N-Number on rudder
N-Number on panel
Fuel tank calibration
Washers for aileron bellcranks
Tensioning bungee for elevator
Flap handle bungee
Spinner final install
Grease on bellcranks
Yellow plug succured on engine spray rail
Nose gear pushrod boots
Path door fiberglass
Install dorsal fin
Oil access door
Two additional cowl fasteners

Starting to apply finishing touches.

I uninstalled all the controls, cleaned and painted them. I cleaned out the cabin, vacuumed it and blew it out with air. Once that was done painting started.

The control stick was ground down for extra clearance .

Sound deadening material will be cut to be floor mats.

Secured the dashboard and panel. Gave the panel good labels. Sealed the weather trim to the windshield and did weather sealing for the skylight. The skylight is riveted in a final install.

Another weekend of finishing work.

Preperations are being made to button the dashboard onto the panel. I filled all the grommet holes in the firewall with high-temp RTV. I also fabricated patches to cover the holes where the Zenith style throttle linkages passed through the firewall. They also received RTV along with rivets.

A new panel light was installed to replace the one that was damaged while in storage.

Label the panel
Patch fiberglass on doors
Final windshield install + sealing
Seal sunroof
Order & install steering boots
Adjust control tensions
Check all cotter pins, saftey wire, bolts
Install elevator VGs
Install dorsal fin
Final upholstrey install
Install oil door.
Replace gear with Grove brakeline drilled gear ( ordered )
Run brake lines
Install jury struts
EAB plaque
Adjust nose strut
Final battery box secure
More transition training
Insurance
Smooth any remaining rough edges.

The engine started without problem.

New punchlist:

Patch fiberglass on doors
Final windshield install + sealing
Seal sunroof
Order & install steering boots
Adjust control tensions
Check all cotter pins, saftey wire, bolts
Install elevator VGs
Install dorsal fin
Final upholstrey install
Install oil door.
Replace gear with Grove brakeline drilled gear
Replace landing gear pads
Run brake lines
Install jury struts
EAB plaque
Adjust nose strut
Install control boots for steering rods.

The engine is almost ready to go. Below is the "punch list" that I could come up with. More is likely to be added

• Install battery
• RTV the FWF firesleeving
• Replace pads on main gear leaf
• Replace main gear leaf with Grove replacement
• Run brake lines
• Elevator cables
• Hang flaperons, connect to push rods
• Wire amp shunt
• CHT calibration, install
• Upholstery for interior
• Install elevator trim motor
• Replace temp tie down stations with adele clamps in aft fuselage
• Replace aileron bellcranks
• Clean off sharpie markings
• Finish re-run of strobe, nav wires & map lights
• Run fuel lines from wings to gascolator
• Install jury struts
• Prime V-Frame
• Cargo net
• EAB plaque
• Steering rod boots
• Install fuel filter
• Fix bad fiberglass trim on passenger door.
• Run AOA line
• Install static port
  
• Install Pitot/AOA tube
• Replace bad rivets
  

I spent a day fixing the horizontal stabilizer. About a year ago a test fitting revealed that the forward mount points for 10mm to far inboard on each side.

The entire skin was unzipped. With some careful measuring and luck, I was able to use two existing holes on each side that were 10mm outboard. Many of the bracket holes to the spar became elongated so I enlarged them to A6. The old holes were filled in with A5 rivets.

I took the electrical system apart... again ( fourth time? ) and used an aviation grade spiral wrap conduit to add order to the wires. I then added a piece of L-Angle near that crossed from the pilot side to the passenger side attaching to the bus mount I had fabricated earlier. This was done forward and rear. These provide a very nice spot to secure the bundles against.

The panel is being put back together on the bench. I found a few small problems with the wiring and am fixing them while it is easy.

I used a rubberizing paint on the panel to make it scratch resistant, insulated and glare resistant. So far I am happy with the results.

Using "The GIMP" I have been creating a series of concepts and variations of the paint job. Taking photos of the project the concepts have been laid over to help judge how it will look on the 3D plane.

I finally got around to finishing my ( new style ) cowling.

The current version of the manual is incomplete and incorrect. I used a combination of advise from Roger at Zenith, the forum and the HBH video.

Here is how I did it:

1) Fit the top and bottom halves together, sliding the top half into the lip. I then made sure the the seam between the top half and the recessed lip of the bottom half was OK.
2) Clamped and taped it together.
3) Determined the center of the top half of the cowl and the center of the airplane. I then extended forwarrd the rivet lines on the side of the fuselage to use as reference for getting it even.
4) I then determined the angle of the cowl and got it centered and even. I used the seam lines on the cowl in conjection with some rivet lines on the fuselage to get it even and centered.
5) Once I had that I then marked where I neeeded to trip the cowling to clear the gear leg and windshield. I only trimmed the gear leg hole a bit, the molding supplied a large amount of clearence. I trimmed a small a amount of the top cowling to clear the windshield and sealing.
6) Once I had the the cowl trimmed I then drilled and clecoed the front four holes to join the top and bottom halves. I determined my safe area of the fuselage flange taped the cowling into place and drilled the cowling into the fuselage flange. I made the holes A4 sized.
7) I removed the cowling. and clecoed the nutplates onto the bottom cowl for the forward holes. I put the nutplates on the "wrong" side so the barrel was pointing away from the plane.
8) I got each plate parallel with the lip of the cowl and drilled one hole with an A3 bit and clecoed. I then drilled the remaining hole.
9) Removed all the nutplates and drilled the center hole out to AN3.
10) Cleaned & deburred the holes
11) I applied a slight countersink to the A3 holes that hold the nutplate using a hand reamer. Use A3 blind rivets to secure the nutplates. Do not drill out the holes on the nutplates.
12) I drilled out the holes on the top cowling to AN5
13) Using a flat riveter head I riveted the nutplates to the inside lip of the bottom half so the barrel pointed into the airplane.
14) I clecoed the nutplates to the fuselage flange where the cowl met and used a similar technique.
15) At this point I did not install the left and right nutplates where the top and bottom halves of the cowling connect to the fuselage.