Finished major construction, ready for the DAR.

Added trim to wing root skins. Secured strobe\nav wires in baggage compartment.

Added tangs to rudder cables to effectively lengthen them. Neutralized rudder and brake pedals. Safety wire and secured rudder turnbuckles. Added cotter pins to all steering assemblies.

Added adele clamps to secure brake lines.

Finished securing wires in hatch.

Fitted scat tubing to oil cooler and re-bonded NACA duct.

Chased down a squeak in the elevator.

Final check for all bolts, pins, wire.

Found prop serial number ( without having to disassemble! )

Did static runup to verify full power and prop pitch. 5500RPM at 11.5 degrees pitch.

Wrote "Fuel On" \ "Fuel Off" placards on floor since stickers would not stick.

Performed fuel flow test at nose high attitude.

Punch List:
FINISH PROCEDURES\MANUAL
Emergency flight refresher ( simulated engine out, ect )

Trim passenger side door fiberglass, add rubber trim.
Fabricate, install streamlined strut covers. ( post first-flight )
VGs on elevator ( after initial test flights )

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

Did a bolt\torque check. Identified all untighted and overtorqued bolts. Replaced all severly overtorque bolts. 95% of all exterior bolts now flight ready. Almost all cotter pins installed, all others marked. Removed the dorsal fin. trimmed the top fuselage skin at the elevator cable exit and moved the reinforcement bulkhead forward to account for the bungee tension.

Ordered some nylon to mitigate rubbing of the elevator cable on the baggage compartment.

Gave the EAB plaque to the engraver. Worked on procedures and manual.

Took an initial weight measurement of 621 pounds.

Punch List:
FINISH PROCEDURES\MANUAL
W&B
Final placement of battery ( pending W&B )
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

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 new punchlist:

Fuel lines run from wings to gascolator
Fuel filter
Run line for AOA into wing
Install ammeter shunt
move solenoid location
Install final wires to bus
Wire batter & alternator together
Install split throttle
Install choke

Patch fiberglass on doors
Order Garmin 496
Create wire access port on dashboard
Final windshield instal + sealing
Seal sunroof
Order & install steering boots
Final instal on position light wiring
Adjust control tensions
Final wire secure in hatch
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
RTV the FWF firesleeving
Run brake lines
Install jury struts
EAB plaque
Instal static port

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