Scott & Tanya Card RV9A build log (N4822C)

I got both P-mags reinstalled. This is my first time setting up timing on one of these engines. I’m learning new details every day :). Anyway, I found that there is a TC mark on the ring gear assembly that aligns with a point on the starter that matches top dead center of cylinder #1. So I positioned the prop at that point. I used some jumpers to keep the pmags grounded as I applied power to them (coil connector disconnected on each unit to keep the coil from firing the plugs). This put them into “setup” mode. I turned the mag drive gear until the little LED on the mag turned green. This is the point where the crank angle sensor is set at top center. I inserted the mag with all the gears all lined up and adjusted so the green light remained on. This is the manual mechanical timing method for the P-mags as opposed to setting a timing angle offset in the software via blowing in the manifold pressure sensor tubing attached to the mags.
With the P-mags secured, I decided to hook up a laptop with the eicad software. I had previously made a serial interface cable to plug the laptop into some connectors that I ran behind the panel from the mags. Very cool toys.

 

  

  

  

 

Ok, I’m finally done sanding on the cowl for now. I did a solid 9hr day today to get it knocked out with final sanding and priming. It isn’t anywhere near final, but is almost exactly as good as I was shooting for just for phase one, pre-paint. Almost all of the pin holes are filled. It will need one more round of sanding primer before paint. Major accomplishment.

 

  

  

  

 

Still priming and sanding the cowl…

Yep, I decided to dive into priming and sanding the cowl. The surface is pretty sloppy with pin holes and imperfections that have to be filled in an iterative process. I’m using UV Smooth Prime from ACS. The first coat I rolled on with a foam roller. That worked pretty well. I think I’m going to spray the next coat. I’m just aiming for close enough with this since it is a very unpleasant process. I’ll pay somebody to take it “the last mile” when it goes to paint.
The frustration of sanding for hours at a time deserved a nice flight so Tanya and I launched in a DA-40 for some pattern practice. What could be more relaxing.

 

  

  

 

I got all of the camloc cowl fasteners drilled and riveted to the attach strips. Next is to simply rivet the side attach strips to the firewall flange and we can call that done. I also picked up some epoxy pigment to use in some thinned epoxy to seal the inside surface of the cowl. The pigment was kind of useless as it wasn’t very opaque. I brushed on the thinned epoxy on the inside surface and am going to go back and paint it white with some high temp engine enamel.