Canopy adjustments / Cable tension

I spent way more time today then wanting to in trying to get the canopy to come down fully. As per instructions there was a little interference with the G3X so some adjustments were made in that area. I also noticed that the rear window was interfering with the canopy. I had known this and was going to adjust when placing the rear window, but forgot to do it with the rear window out, so I had to carefully adjust the front portion of the rear window to allow space for the canopy to clear. I also noticed that the left side of the canopy didn't overlap the side skins. I am not sure why, so I had to bend out the canopy skirt slightly. Then after several hours of adjusting here and there I was able to get it to close.  

I then checked and adjusted the cable tension as per instructions. They were tightened to about 40-45 lbs. I will check it again once in the hangar.

Time: 8.5 hrs.

Canopy installed

Lower Cable tension

Upper cable tension

Swivel barrels locked

Canopy sanding, paint flap handle

I sanded the canopy and then placed a layer of epoxy. I then painted the flap handle and the detent bracket.

Time: 0.75 hrs.

Epoxy layer

Painted flap handle

Painted flap detent bracket

Prime fuel tank, SB 16-08-24, canopy trim, interior paint

Quite a bit got accomplished today. Started by drilling out the holes in the canopy to gain access to the bolts. I drilled a little too low initially, but those areas can be filled in later.  I was then able to remove the canopy after a lot of careful work loosening up the edges. Tape and paper was removed from fuselage. It took some work with acetone to get the remnants of the duct tape off the metal.

I then primed the fuel tank and installed the safety wire on the seat backs.  I worked on the canopy catch removing the rivets as per update and installing catch. I also worked on SB 16-08-24 since I still had good access to the engine mount brackets.  The rivets were replaced with new as per SB.

I then marked and trimmed the canopy and filled in some voids.

There was a new flap knob that could be placed to minimize pinching of fingers, so I installed it. I then tried in the interior to look and see what areas needed painted as I am only painting the interior in the locations that are not covered by the interior package. Once taking note of the areas to paint I taped off the interior and primed and painted.

Time: 9.25 hrs.

Drill holes in canopy

Seat back safety wire

Canopy off

tape removed

Rivets removed for canopy catch

Upper FWD fuselage removed

Rivets removed

New rivets installed

Bottom trim line marked

Template placed

Template traced

Canopy trimmed

Voids filled in

Flap knob replaced

New flap knob installed

Canopy catch installed

Seat cushion tried in

Carpet tried in

Control stick

Power plug area

Seat belt connection

Interior tried in

Seat hinges

Head phone jack

Interior taped

Interior painted

Cabling/ pitch servo

Started off today by attaching the rudder cable links. It was a little tight of a space to get in there but was able to get it done. I then joined the stabilator cables and tightened them some.  I need to borrow a cable tensioner if I can to get the proper tension.

I then started on installing the Garmin autopilot servos. Pushrods were fabricated as per plans and then the pitch servo and rod was installed.

Time: 2.25 hrs

Rudder Cable links

Stabilator cable tightening

Autopilot pushrods

Pitch servo

Pitch servo and rod

Wing attach

Finally a nice day to take the plane out of the shop so the wings could be fitted and flaperon torque tubes installed. N and S helped me a lot today.  It took a little work to get the right wing fully in.  Finally used a tiny bit of tap on the spar pin and it went into place.  The skins of the wings were marked at 3/16 inch as per plans and I will trim at a later date.

The flaperons were installed. I had to open up the space between the plastic blocks on the flaperon torque tube in order to get the actuation bracket to fully seat.  Once seat the torque tubes were matched drilled to the flaperon torque arms.  The wings, the flaperon torque tube, and the flaperon arms were then removed. The holes were enlargened and then the arms and tubes were then reinstalled.

It was a great day to get this part accomplished.

Time: 5.75 hrs

Wings installed

Fitting actuation bracket to torque tube

B showing off plane

Wing spars in fuselage

Right flaperon attached

Left flaperon attached

Fitting flaperon actuation brackets into the flaperon torque tubes

Shims placed on left flaperon

Torque tubes clamped for drilling

Torque tubes bolted

Flaperon handle / cabling

Made some progress today on the flight controls and cabling. I started with placing the detent bracket and completing the flaperon handle. I then placed the spacers in the flaperon torque tubes using epoxy and rivets. I used a piece of scrap angle to make sure space was maintain between the blocks.  I then used some scrap wood from the crate to fabricate the rudder pedal rigging stops.

I then ran the rudder cables through the proper holes and attached them where indicated in plans. The rudder cable links were then fabricated.  I will wait to fully secure the rudder cables on the forward end until after I have installed the flaperon torque tube.  I need to try in the wings before I want to install the torque tubes, so I am waiting on a nice day when we can pull the plane out of the shop and have extra hands to try on the wings.

The stabilator cables were then ran and attached at each end.  They need to be connected in the middle, but again I will wait until the flaperon torque tubes are installed.

Time: 6.5 hrs

Flaperon handle / detent bracket

Flaperon torque tubes

Rudder pedal rigging stop

Running rudder cable

Runing rudder cable

Pulling rudder cables

Marking rudder cable links

Rudder Cable links fabricated

Running stabilator cables

Forward stabilator cable/pulley

Rear stabilator cable attached

Rear stabilator cable attached.