Scott & Tanya Card RV9A build log (N4822C)

Still just picking parts and installing. I wanted to get the painted brake pedals off the bench so I installed them and put together the rudder pedal assembly. I did not install it in the airframe quite yet. I used an AN3-60 bolt for the pedal hinge points as opposed to two bolts that tend to bind upon rotation. The -60 is a bit long so I used a few washers.
I assembled the Andair fuel selector valve on the mount plate with some countersunk AN3 bolts. I previously had this put together with normal AN3 hex bolts but could see that I was going to be scraping my knuckles on the bolt heads. I like this much better.
With the rudder cables installed, it was time to finish up the rear cable exits. I had purchased the exit fairings from some time ago. I cleaned them up and riveted them into place and installed the adel clamp on the guides on the inside.
Next up, I mixed up some of my favorite goo, Proseal. I sealed the firewall recess, heater selector, and brake reservoir assemblies to the firewall, as well as put a little glob of proseal on the static port-tube and faired the rudder exit fairings. Tanya helped me rivet the firewall recess on for good. I only mixed up 20g of proseal and applied with a syringe and still had a lot left over.

I downloaded the installation diagram of the GRT magnetometer which has exact dimensions of its case which I used to fabricate a mounting bracket for it in the rear upper fuselage. My bracket is made out of .032 sheet. The bending brake worked great and helped produce a very rigid assembly. I spent a bunch of time with a level and sight making sure this thing was lined up right in each axis.

I should have an order arriving soon from Vans with some fun stuff to work on: Fire extinguisher mounting, main battery, seat belts and 5th point mount kit.

 

  

  

  

  

  

  

  

  

 

Today I installed the flap actuator system including the FPS. I did a little pre-assembly on the bench then moved it to the airframe. I fought with the safety wire for a bit but got it worked out. I’m waiting until I install the aft vertical brace to finalize wire lengths and mounting of the FPS unit. I’m waiting to install that brace until I get the fire extinguisher that I want to install on it. The fire extinguisher is in an order being delivered in a couple of days :).

After playing with the flap stuff I decided to tinker with the overhead lights. I’ll never admit how much actual time it took me to wire them up. They work great and are ready to go.

 

  

  

  

  

 

I got the rudder cables and fuel vent lines installed (for the last time). I can’t tell you how much fun it is to be able to basically just take parts off the shelf that have already been fully test fit and just do final install.

 

  

  

 

Assembly continues.
- flap control weldament
- canopy latch weldament
- canopy latch side skin brackets riveted on
- canopy latch linkage almost complete

I also spent a little time playing with my new (way overkill) digital soldering station.

 

  

  

  

  

 

I got the garage cleaned up after the painting session this weekend. The fuselage is unmasked and painted parts are slowly being put away. I’m quite happy with the finish. It is about what I expected.

Then, on to the fun part. Assembly! Yeah! I riveted on the instrument panel attach brackets on the side rails. Some were squeezed with the longeron yoke and others had to be shot (Tanya helped). Then I decided to bolt up the tip-up canopy strut attach brackets. Chugging along, I attacked the static system tubing. I used a pot of boiling water to soften the tubing to push onto the plastic T. That worked great. I also used the boiling water to relieve the storage crimps in the small 1/8″ tubing that attaches to the ports. The static line was run through previously fabricated (at this point, just about everything has been “previously fabricated”) tubing clips along the left longeron all the way forward.

I figured out that I didn’t have all of the assembly hardware for my TruTrak autopilot so I called them and got that on its way.