Exhaust Vents

In looking at Steve Henry's plane and one Chris Wallen did, they have two different approaches to venting the heat out the side of the cowling. Steve has one big fiberglass vent whereas Chris has a stacked vent system. I decided to go with the stacked system changing it a little from Chris's rendition. Mine would be three equal vents per side. They won't stick out quite as far as Steve's but a little more than Chris's. Mine would be made out of aluminum like Chris's, not fiberglass like Steve's. Because I am running out of time before my move, I wanted to keep it simple and get it done. They are static and remain in a fixed position.

Cheek Windows and Cowling

Yesterday I finished up the day by making a new cheek window. I fabricated a pair a couple of years ago and when I went to install them, I realized I cut them too short at the firewall. So, I had to remake them. Fortunately, the screw holes were already done and were correct, so I was somewhat easier to simply duplicate them. Anyway, got one made up last night and the other this morning. Got them both installed.

Then it was finally on to cowling. I just dove in and eight hours later I had the cowling mounted. I still have quite a bit of final sanding/fitting to do, but I'm happy with the result so far. Tomorrow I'll cut out the sides for the vents.

Exaust System

I ordered some 2" 321 Stainless 90 degree tubes and a flex joint for the exhaust system. While waiting for that stuff to arrive, I had to come up with a way to mount the muffler (Burns Stainless, CA), and decided to hang it from brackets bolted to the tubing where the brake pedals are. Being a SuperSTOL, I can't attach the muffler to the landing gear as they do with the Highlander's. So, I cut a couple of steel brackets and drilled them for Adele clamps, sliced the fabric, pushed them through and attached the Adele clamps. Then I cut a couple of pieces of thick rubber to use as hangars/cushions for the muffler. 

When the tubing arrived my friend Vernon Rich gave up his Easter Sunday to come fab up the exhaust system with me. We spent the morning into early afternoon cutting and tacking up the exhaust. He took the tacked pieces back to his shop and finished welding it all together that afternoon. I picked it up and confirmed the final fit that evening. Many thanks to Vern!

Radiator Scoop

More cowling. Cut and temp fit the radiator scoop.

Doors and Windows

Finished up the doors and windows today. With the exception of the window latches, they're not closing tightly as they should. I'll have to come up with something to fix them.

I also re-installed the boot cowl so I can start on the cowling tomorrow.

Windshield

Got the windshield on this afternoon. Took a little fiddling with it to get it to go back in place and line up. Eventually got it. I had to make a trip to ACE for some longer stainless 6-32 screws and more washers. It's starting to look like an airplane.

Fuel System

Installed the vent lines and made the final fuel line connections today. Once everything was hooked up, I poured a three gallon mix of distilled water and denatured alcohol into the tanks to test for leaks. I let the mixture sit for several days and was able to make a loop at the firewall so I could run my fuel pumps. This pumped the mixture up to the fuel sensors (not through them) and back to the header tanks. Doing this allowed me to test the cockpit lines under pressure (both pumps running). I did have a couple of leaks so it was fortunate that I was running this mixture instead of fuel.

Over several days I was able to fix all the leaks and run it without issue. I let it set several more days leak free before draining the system of the mixture. The denatured alcohol will help the water evaporate out. Once I put fuel in it, I'll be testing the engine over many days and will for certain eliminate any moisture left in the system.