March 1999
March 2, 1999
Began strip-down of motor for inspection. The bottom plugs are difficult to get at and require the following tools at minimum: 5/8" and 1/2" wrench, slotted screwdriver, 7/64" allen key, channel lock pliers, special 3/4" and 13/16" deep socket. Form a Gasket (blue) is also required for re-assembly. These items should form part of the A/C tool kit.
After removing the cylinder head cover form the nos. 1 & 2 side a discolouration was noted on the interior surfaces as if the oil had been overheated. This was not noted on the other side. It appears #2 cylinder may have been running hot (as this is the front cylinder I am at a loss to explain). Careful inspection of this area will be required.
March 4, 1999
Complete fitting of turtledeck to airframe. Some trimming was necessary. Floxing into position next.
March 5, 1999
Varnish (2nd coat) interior of fusealage. Drill 1/8" drain holes at the aft corners of each bay.
March 7,1999
Continue strip-down of engine. Overheating on #2 cylinder was being caused by an exhaust leak. The exhaust system is the Revmaster "Anti-Revisionary" system originally designed for the Q2. Three of the four header pipes had not been welded into the collector pipe located under the left cylinder bank (cyl #1 & 2). Carbon from the leak was evident on the engine case and underside of baffles on that side. All of the header pipes will have to be welded into the collector to ensure a good seal. Other than this obvious installation error the exhaust system seems thoughtfully designed and in reasonable condition.
Flox turtledeck into position.
March 9 - 11, 1999
Temporarily install carb and lower intake manifold to check clearances and cable lengths. Order a bunch of really expensive stuff (fortunately I have a special credit card with a P.O.Box billing address and Wicks sends everything in plain brown wrappers)(God I feel so cheap).
Sand off gelcoat 1 1/2" up sides of turtledeck. A rotary sanding tool (Gemlok or equivalent) works best here.
Apply 2 layers of 6 oz cloth in 3" strips over the joint between turtledeck and fuselage. As with most of the lay-ups I am using West 105 resin with 206 hardener.
March 12, 1999
Begin fairing of turtledeck to empanage.
March 13 - 14, 1999
Install radio...(AM/FM/Cassette in Wife's 97 Hyundai). You single guys may not think this activity advanced the project.
March 15 - 16, 1999
Fabricate and install inspection cover for upper elevator horn. Burned up a few brain cells trying to come up with something magical here...then gave up.
March 18, 1999
Foam in fairings between vertical fin and turtledeck.
March 21, 1999
Glass-in fairings between turtledeck and empanage (upper side).
Install a small sub-panel beneath the instrument panel (left side) for throttle and mixture controls. Throttle is a standard collete locking push-pull unit. Mixture is a detent friction (semi-lock) type as used in 1970's Cessna150s. After spending a lot of hours in these little crates I have an enormous respect for the design. Since it's hard to pick a more dependable aircraft I usually try to copy the 150 when in doubt.
March 22, 1999
Continue installation of throttle and mixture controls. It's a strange feeling, drilling holes in something you've spent so long putting together. Perhaps I'm spending too much time here in the garage. The voices say that it's time to do something different, like clean the guns...
March 23, 1999
The new interior just back from the shop
.March 24-25, 1999
Locate gascolator on firewall. The center location offers the shortest run with the fewest number of fittings but does place the main fuel line in between the pilot and passenger's feet. The gascolator is held to the firewall by a bracket of .040" aluminum.
March 26-28, 1999
Fabricate gascolator bracket and install gascolator. Fuel line is 3/8" (OD) aluminum tube up to gascolator. From gascolator to engine is 1/4" (ID) hose.
Clean engine. Remove oil cooler and filter assembly. The Stilco filter assembly was replaced with a Fram PH16 spin on unit per Revmaster recommendations.
Remove oil sump, check for particles, clean and replace with fresh gaskets. Remove breather assembly, clean and replace with fresh gasket.
March 29-30, 1999
Clean and check carb. Revmaster recommends placing a shield around gascolator to prevent possibility of vapour lock.
March 31, 1999
Locate battery on firewall. Due to proximity of battery to exhaust it will be contained in a full aluminum box even though it is a manifold vent type and as such could be placed in a rack. Battery is an Interstate YHD-12 28 amp hour motorcycle type.
