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03May01, 4 hours - Flaps skins have arrived. Trimmed a
bit. Installed fuel lines from main to valve, and valve to pump.
04May01, 5 hours - Trimmed flap skins to fit. Laid up flap
spars.
05May01, 6 hours - Finish fit the flap skins. Bonded flap top
spar, laid up spar to web glass. Prepares trailing edge board for
left side.
06May01, 4 hours - Inspected & closed left flap. Worked on
trimming & fitting short tip nav lamps.
07May 01, 4 hours - Inspected left flap. Fit is much better
than before, with perfect lineup with the aileron and an arrow straight
trailing edge. Moved trailing edge board & inspected and closed
the right flap.
08May01, 2 hours - Removed trailing edge board, inspected right
flap. Dead on, just like the left! I lost about a month
& $400 to the flap rework, but I'm glad I did it.
12May01, 3 hours - Laid the 2-ply flap bridge, prepared for
installation.
13May01, 2 hours - Installed the flap bridges. There will still
be a step at the outboard end, but it will be much smaller, about the
same size as on Dace's bird.
19May01, 8 hours - Laid up one more layer of glass in the
bridge. Filled the bridge with q-cell/fiber/cabosil mixture, then
laid an additional layer of glass on top.
20May01, 6 hours - Sanded & filled bridge top. Capped the
outboard flap ends, and the tiny step at the outboard end of the
bridge. Sanded short wingtips even at leading edge.
24May01, 2 hours - Began fabrication of fuel valve position
assembly. This consists of a an aluminum plate on top of the wing,
with a bushing for the valve stem, and three micro-switches. A cam
made of 3/16" Al on the stem actuates the  micro-switches.
With a switch for wing, header & off, I'll be able to positively
identify all positions, and set a warning for in between
positions. When set to a tank, the computer will totalize fuel
burned from that tank, and highlight time on tank, time left on tank,
and fuel level of the active tank.
25May01, 2 hours - Completed assembly of the fuel valve position
switch block. Installed wingtip fuel vent lines. Fit pilots
split seat pan.
26May01, 9 hours - Fit short wingtip lenses & prepped for capping
tips. Attempted to complete nav light fabrication by fastening
ground to metal lamp shell. The material seems impervious to my
drill. I'll need to find a new way to fasten the ground, or a new
lamp holder. Began wiring termination in the seatpans. Most
of the wires exited to right of the A rib, as recommended. This
made the task of routing past the flap motor very difficult. I
pulled most of the wires & rerouted them to exit in the right front
corner of the right seatpan. Three clamps under the right edge of
the pan cutout brought the wires back behind the flap tube, then down
into the seatpan.
27May01, 7 hours - Continued wire termination. All grounds go
to a common terminal block. The nav power of all three lamps go to
another block. The balance of the switched power wire are
terminated behind the seatpan with a 12 pin Deutsch connector. The
wires for the fuel probe, autopilot and flap position pot have their own
12 pin Deutsch. A third connector (6 pin) is ready to carry the
strobe & nav to the tail. Schematics - Printable GIF,
Screen Size GIF, Visio.
28May01, 5 hours - Completed wiring. My paint job in the lens
area of the tips revealed many sins in finishing the surface.
Ground it off to try again.
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