Date

I needed to stiffen the baffle area around the oil cooler due to the number of builders who report baffle cracks developing in this area.  I used 3/4" AL angle and riveted it along the rear.  Later, I will add a brace from the stiffener to an engine centerline case bolt.

 

I also finished securing the lower baffle seals around the #2 and #4 cylinders by using safety wire instead of the threaded rod.

I drilled the hole for the fuel purge return line in the lower right corner of the firewall.

I need to finish up some loose wiring so I started by wiring up my P-Mag and E-Mag.  I also connected the manifold pressure line to each Mag.

 

I also had previously installed each CHT probe so I measured the sensor wires allowing for a "drip-loop" and crimped on the connectors.  After heat-shrinking the connectors I tied up the loops with zip ties or Adel clamps.

I also finished installing the bolts and oil line fittings for the oil cooler.
 

Throttle and Mixture Cable Installation

I received my cables today from Van's.  I started with the throttle cable and ran it through the firewall to the quadrant in order to determine how to fabricate a bracket for attachment.

 

Terry Tibbits came by today to help me pre-oil the engine.  I bought an oil pressure gauge and we were able to spin the prop using the starter until it read 40 psi.  Good enough.
 

Purge Valve Cable Install

I also installed the purge return line to the firewall bulkhead fitting.

 

Then, I fluted the airbox flange in order to create a slight upward slant to match the cowl inlet.  I drilled the mounting plate to the airbox and installed the filter clips and platenuts.  I also riveted the fiberglass lower portion to the top plate.  With it all together, the fit is perfect.

I then cut the hole in the bottom of the airbox for the bypass gate.  I drilled it and installed the base using RTV as a sealant.  I also drilled two #30 holes for drainage.

 

While I had the epoxy mixed, I added some flox and bonded and riveted the right wingtip upper hinge.

I safety wired the FAB plate to the throttle body.

I also wanted to finish the top cowl so I drilled and clecoed the "elephant ear" ramps.  By placing the top cowl in place I was able to see how much to trim off the baffeling.  I then epoxied the ramps in place as well as the oil door latch cable and installed the top cowl to allow the epoxy to set with it all in place.

 

I then riveted the seal on top of the air box using RTV to seal the gaps.  On the inside of the lower cowl I used E-6000 epoxy and clamps to secure the seal.  This area is too tight to get a pop rivet gun into.

I then removed the empennage fairing and trimmed it to final shape.  I then drilled each screw hole for platenuts in the areas I could reach.  I will need to remove the VS and HS in order to rivet the platenuts.
 

I then focused on attaching the gasket seal on the baffles.  This is an iterative process that involves cutting 3.0" strips of the seal material and drilling it to the baffles.  Starting at the rear and moving forward along the sides you have to drill and cleco the material on each baffle section in case you ever need to remove the baffles.

I also drilled and installed the air inlet seals.

 

I spent the rest of the day working on my wing tips.  I mounted each wing tip on the wings and measured the W-916 wing tip ribs.  Due to interference with the hinges, I had to trim the ribs to fit.  I then removed the left wing tip and drilled the rib to the tip.  I also fit and started drilling the W-931 wing tip rib.
 

I installed the rudder cables to the rudder bars since I have the correct clevis bolts now.  I also went ahead and drilled the brake master cylinders to the pedals.

With Karl's help I crawled into the tail and covered the loose wiring running aft with corrugated tubing for chaff protection.

 

I had a site visit by Vern Darley today.  Vern will be helping me out in several ways.  I will be taking my transition flight training with him on March 7th.  He will also be serving as my DAR and this was the first time he has seen my project.  (Fortunately, he found no fatal flaws).  Lastly, Vern will be conducting the first flight for N16BL.

After Vern left I fabricated the lower cowl support bracket.

 

I also fabricated and installed the main fuel line running from the boost pump to the firewall.
 

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