Monday, 6 October 2014

6th October 2014 - Final To-Do List

The bad weather today gives me an opportunity to pull together a list of all the outstanding items to complete the build. Many of the items will just take a few minutes to do but there are a number that will take a few days each. However, overall the end is in sight :-)

 I'll mark items in green as they are completed. 

Engine:
  1. Build and test a voltage regulator for the alternator. I'm doing this using the L9911 chip.
  2. Install the voltage regulator and re-install alternator
  3. Install ignition leads
  4. Install Oil temperature sender
  5. Install grommet in baffles for engine breather tube
  6. Install additional bolts for the starter motor and propeller spacer and wire safe-tie where applicable
  7. Install the propeller and spinner, safe-tie the propeller bolts
  8. Test installation of lower cowl with spinner in place, trim front of baffles as required
  9. Install the seal which will connect the airbox to the lower cowl
  10. Drill the cowl for access to the gascolator drain
  11. Partially fill the fuel tank, check the fuel flow with gravity and the electric fuel pump
  12. Calibrate empty setting on fuel level gauge
  13. Remove/clean/reinstall  the fuel tank filter
  14. Remove/clean/reinstall the gascolator filter
  15. Test run the engine checking; oil temperature and pressure indications, cylinder and exhaust gas temperatures, vacuum system, charging system.
  16. Mount a high power TVS across the alternator output
  17. Install the over-voltage crowbar circuit
  18. Procure, fit, and test replacement oil temperature sender
  19. Adjust vacuum regulator to get vacuum into "green" arc, if not possible replace regulator and/or vacuum pump as required
  20. Remove/clean/reinstall the carburettor filter
  21. Compression test the cylinders, rectify if required
  22. Remove engine, paint, reinstall
  23. Inspector sign-off for engine installation
  24. Inspector sign-off for fuel flow
Cowls and Spats
  1. Install heat shield to inside of cowl where close to exhaust system
  2. Prime cowls, fill pinholes, sand and re-prime until smooth
  3. Paint cowls with Insignia white Eko-Poly
  4. Apply glass cloth reinforcement to top of leg fairings
  5. Prime and topcoat leg fairings
  6. Prime and topcoat wheel spats
  7. Fabricate, paint, and install intersection fairings for wheel spats to leg fairings
  8. Fabricate, paint and install intersection fairings for leg fairings to fuselage
Panel
  1. Install P1 headset power outlet
  2. Remove Transponder, return for repair to display, refit
  3. Replace battery in KMD150
  4. Update database in KMD150
  5. Set Mode S address for G-CIJY  in transponder
  6. Install P2 PTT switch in panel
Fuselage
  1. Print knobs for the fresh air vents and install the vents.
  2. Get new lens for rear navigation light, paint lens holder and install
  3. Rework fabric cover over left door internal structure. I'm not happy with the current result.
  4. Apply EkoFill/EkoPrime to left door internal skin
  5. Topcoat left door with white EkoPoly
  6. Mask fuselage as required and paint internal areas behind rear door post and in front of rear window
  7. Redo fabrication and installation of two-off door and  two-off rear fuselage side windows using polycarbonate sheeting rather than acrylic
  8. Install windows in rear fuselage and doors
  9. Repaint seat floor panels and install
  10. Repaint left door jamb panel and install
  11. Fabricate internal door handles and install
  12. "Print" and install covers for the areas in the fuselage where the elevator torque rods pass through the fuselage fabric.
  13. Install baggage compartment panelling
  14. Install seat belts and install cover over flap lever, must be done at the same time
  15. Paint seat backs
  16. Install seat backs and panel between seat backs
  17. Install doors
  18. Install wings and design/fabricate/paint/install fairing to cover the gap between the wing and fuselage
  19. Design/fabricate/paint/install strut to wing intersection fairing 
  20. Install GPS antenna
  21. Install radio antenna
  22. Inspector sign-off for Fabric and dope for quality
Controls
  1. Make drainholes in control surfaces
  2. Assemble wings to aircraft and install flaps and ailerons
  3. Inspector sign-off for complete mainplane structure
  4. Inspector sign-off for flying control assembly
Trimming
  1. Re-paint spinner and paint backplate to match
  2. Purchase and install self-adhesive registration lettering for G-CIJY to fuselage and left wing
  3. Design small-scale colour trim to "finish" aircraft
  4. Purchase and install self-adhesive fine-line colour trimming
  5. Polish paintwork
  6. Fabricate and install boot for control column
  7. Upholster seat backs and seat bottoms, use velcro to fix in place
  8. Cut carpet to fit foot well and get edges bound, secure with velcro
Preparation for test flight
  1. C of G check
  2. Component record datasheet completed
  3. Identify test pilot
  4. Request permission to test fly from LAA
  5. Transport to suitable airfield
  6. Compass swing
Other
  1. Calibrate full fuel setting on fuel gauge when tank is first filled
  2. Install/UV block/prime/paint tapes to join horizontal stabilisers to fuselage once angle of incidence of horizontal stabilisers is finalised.
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