[79FT]: Building Things

Tagged with "Annual":

Annual 2019: April 6

...wing root fairings


On: Apr 06, 2019
In: [Chickenhouse Charger] 2019 Annual
Tags: 6781G, MA5 Charger, Annual

Only had a few hours today, so decided to concentrate on taking off the wing root fairings. As I mentioned before, the "back-side accessible" screws were set up to have nuts on them rather than nutplates. Well, I don't know about that accessibility....

It ended up being 3 hours for ~30 screws.

Root fairing off

Root fairing off

Most of them on the back side of the wing require you reaching with a wrench thru the rear cockpit, and my arm is just barely long enough to do that successfully. Since nuts are nyloc, no way I can hold them with my fingers - they need a socket.

Some of those nuts are in a U-type channel over which the fabric is glued, and some of the holes are off-center: making it impossible to put a socket over them.

I could've ground a socket down; but I don't have a grinder - so especially one of the nuts took a while to get off. And oh, you have to do all that without dropping the nut and the washer onto the floor (and having them go into the tail). So the process looked like this:

  • Get your hand in, try to put the socket over the nut.
  • While holding the ratchet, try to put the screwdriver into the screw w/o missing it and poking a hole in the fabric.
  • Undo the screw, almost.
  • Remove the socket, take a strong magnet.
  • Finish undoing the screw, hoping that the magnet will catch the washer and the nut.

Having magnetic sockets helped. They weren't deep enough to grab most of the fully tightened nuts because screws protruded from them. I used them as magnets sometimes, and sometimes used my magnetic "fishing for lost hardware" probe.

Now I'm writing this, I realized what I should've been doing is using a long extension and a 90 degree adapter on my socket. Damn! But this still doesn't solve the problem with some of the nuts that were hidden almost behind things that were in the way (ie, a trim control wheel's attachment structure that's welded into the fuselage).

One of those pesky nuts

One of those pesky nuts

I'm considering replacing those nuts with Tinnerman-type and screws with sheet metal screws thru Tinnermans. I'd put some anti-chafe tape inside the U-channel, and then Tinnermans on top of it. Since Tinnermans are long, when undoing (or tightening) the screw, they will turn and touch the side of the U-channel, which will act as a wrench.

Wing attachment - right side

Wing attachment - right side

And that's literally all I got done today. Just took those damn screws out.


A grease-job landing is 50 percent luck; two in a row are entirely luck; three in a row and someone's lying.


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Tagged with "Annual":

Annual 2019: March 30

... getting familiar


On: Mar 30, 2019
In: [Chickenhouse Charger] 2019 Annual
Tags: 6781G, MA5 Charger, Annual

Decision

After getting the Charger, I have decided to fix a few basics.

  • Clean plugs
  • Change oil
  • Give her a good look over

Getting a bit ahead of myself, a series of coincidences (airport closed, baffles' condition, intake leak, and others) made me decide to go thru the annu... sorry, Condition inspection (damn, will have to get used to new nomenclature :) ).

Notes

Cowling came off.

Cowling off

Cowling off

Discovered a few booboos:

  • Cracked cowl inlet ramp: need to stop drill.
  • Baffle seal behind the inlet ramp is turned the wrong way (Glenn was complaining about high temps - one of the reasons, hmm?).
  • Top baffle seals are too hard and sag in few spots.
  • One of the air take-offs off the ramp has almost un-riveted itself.

Since I will need some helps with skills and tools with riveting, and we'll need to pull the prop to change (and turn the right way) the seals, decided that I will put her thru annual.

Studying the systems (I was mainly concentrated on fuel and other al lines and hoses to see where things go), discovered a few things, too

  • She has the Rotec TBI-40-MKI TBI installed, which requires a 40 mesh filter upstream of it. The only filter besides finger strainers in tanks is gascolator, which goes down to 72 micron (0.003) only. Need to get a hold of Rotec people and discuss this situation.
  • The "low" end of the tank (in 3-point attitude) has a very nice drain fitting + drain cock draining behind the cowl. I am seriously considering adding a quick drain there - that is the lowest point of the tank in 3-point. My thinking is: water collected in the tank, goes to that lowest point; but there's not enough of it to go thru the take-off (which is in the middle). Then, when I raise the tail, it slushes forward, goes into the take-off, and reaches the engine right when I am just off the runway. Not Good.
  • Some un-critical drain hoses are clear vinyl and hard as a rock. For now will replace them with clear polyurethane, and if that hardens, with rubber.
  • TBI needs positive stops on the throttle quadrant. Need to check if they're present and adjust as necessary.
Crack in inlet ramp: stop drill

Crack in inlet ramp: stop drill

Inlet ramp baffle: turned the wrong way

Inlet ramp baffle: turned the wrong way

Inlet ramp's take-off flange - un-riveted itself

Inlet ramp's take-off flange - un-riveted itself

TBI

TBI

TBI - Regulator Side

TBI - Regulator Side

TBI - Throttle linkage

TBI - Throttle linkage

Electrical fuel pump and gascolator

Electrical fuel pump and gascolator

#1 bottom plug - in pretty good shape

#1 bottom plug - in pretty good shape

Engine compartment right side

Engine compartment right side

Fairings

Spent the rest of the day taking off fairings and access panels. This is the first thing I thing could've been done better here methinks. Everywhere where it was deemed that the back side would be "accessible", Remo used #6-32 nyloc AN nuts on machine screws instead of nutplates. Well, some of those nuts are not accessible, and I gave up on quite a bit of them around the rear wing root fairings.

Need to standardize on fasteners' length so that I don't juggle 10 different screw sizes.

Gotta love that easy access!

Gotta love that easy access!

Flying wires' fairing

Flying wires' fairing

My laborers for the day working on wheelpants

My laborers for the day working on wheelpants


"I don't mind altitude separation as long as they're not on top of each other."
-ORD ATC



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