It is Done: As-Built Constructed Airplane

After 5 years and 1 month, it is done.  Looking back my first post was September 25, 2006, when I began organizing the parts.  The twins were two and baby Reagan was yet to be. 

I pitched the Kiev prop and torqued all of the bolts and reassembled the cowling.  The plane is now ready for determining the empty weight center of gravity. 

 

Here is a canopy cover I obtained from Rans to protect the lexan from UV damage and hopefully provide a little theft deterrence.

Here is the new inflatable tailwheel I obtained from Rans to replace the provided one.

Final Install: Misc. Interior Trim Pieces and Hardware

Following of the rigging of all the cables and such in the cockpit, I was able to get some trim pieces fit and installed.  Here is the Station 3 Closeout in front of the baggage area.

Cup holder for non-adult beverages, of course.

This pic shows the push-pull tube cover installed.

And a closeup...

I installed a map pocket on each side of the front seat cockpit, plus installed the smallest commercially available halon fire extinguisher on the floor board.

The right map holder contains my recently received FAA registration; 5-Romeo-Alpha is now official!

Due to my kit having the older "bubble" lexan windows, I needed to have custom-built, longer door upcatches made (at no charge by Rans).  Here is the left side.

Side note:  Just reconned the Houghton County Airport grass in-field area with my truck.  Turns out there is a 2,100 ft. long grassed area between the main concrete runway and taxiway, within a 100 yards of my hangar.  Lit up the truck to 50 mph down the CL and found it totally smooth: I've found my runway.  Will allow me to simulate takeoff/landings from conditions similar to my developing airstrip and will be a whole lot more forgiving on my soon-to-be-installed bush tires and 8-year-old-rusty crosswind technique.

Final Rigging: Flaps, Ailerons, Horiz. Stab., Elevator and Rudder

Over a period of time, I adjusted all of the above to specified deflection angles and tensions, as appropriate.  The airframe is completely rigged now.  Used my Iphone (and corresponding application) for all of the vertical deflections; measured the horizontal rudder deflection more conventionally.  Had a local A&P come over and set the 25 lb tension in the aileron cables with his tensiometer.  I torque sealed all of the jam nuts.

Final Install: BRS

I mounted the front and rear rocket activation handles and routed the cables back to the chute tray mount.  Similar to a gun, these cables, when pulled, actuate a firing pin at the rocket, which detonates a primer, which then ignites the sold fuel rocket.  Since both cables are connected to the firing pin, they provide some redundancy, should one fail. 

I then assembled and mounted the rocket assembly to the tray and connected the rocket lanyards to the chute.  The lanyards (not shown) will pull the chute out of the plane on deployment.

The rocket is housed in this launch tube with cables and firing pin at the bottom.

The rocket would exit the top of the tube and pierce the fabric on deployment.

 The four airframe bridles are all attachedt to a common carabiner.  From there a single bridle runs to a carabiner which is connected to the parachute.

Some additional pics showing bridle routing:

Flap Fillet and Wing Gap Seal

With great relief, installation of these two trim pieces complete the entire painting phase of the project. 

Final Install: Jury Struts, Flap Teleflex, Aileron Cables

I got the jury struts installed which provide midpoint support to the long main struts.  Of key importance if plane ever flys inverted and main struts go from tension to compression.

The aft end of the rear jury strut attaches to a horn that retains the fuel vent tube and flap teleflex cable.

Here is the completed assembly with painted exit fairing and teleflex cable connected to the flap horn.

Here the flap teleflex cables attached to the flap handle.  The lines are routed so that the floor trim piece will fit.

I also hooked up the aileron cables.

Here is the completed aileron push-pull rod exiting the aileron exit fairing and attachment to the aileron horn/spade.  The push-pull rod originates from the aileron bell crank which is where the aileron cables terminate.

Rigging: Wing Washout/Fuel Gauge Calibration

Today I set the wing washout or twist in the wing.  The inboard side of the wing is set to have a higher angle of attack then the outboard side.  As a result, the inboard side will buffet and stall before the outboard side where the aileron control surfaces are located.  I had to get the wings level, so I used an adjustable stand along with a level to accomplish this.   The level was taped to the bottom of a 2x4 and 1/4" shims were taped to locations corresponding to the spars.  Once the wing was level I then moved outboard beyond the spar attach points and added another spacer on the TE side and adjusted the rear spar fitting until level was indicated.  This was a simple method Rans came up with to get the washout to spec.

Since the plane was level, I then added 1.25 total gallons of fuel to the tanks.  This quantity corresponds to the "unuseable" portion of fuel in the tanks that will not drain out.  Once added, this level was noted on the wing root sight gauges and the "zero" line on the fuel level decal was place accordingly.  I obtained a fish scale to get the precise quantity of fuel in each tank, in this case 3 lb 12 oz per wing tank.