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Sonex 815 Build Logs
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Date: 11-28-2009
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Number of Hours: 4.00
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Manual Reference:
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Brief Description: Reassembly
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Started with the fuel tube between the filter and firewall fitting. I had made 3 to choose from. I thought the shortest would be ok, but it was too short! Tried the original one, and it was still too tight. The firewall had oil-canned a little with the hose on the engine side, so I thought it might change the alignment of the bulkhead fitting a little. Then tried the medium length one - a little persuasion on the upper nut, but it fit pretty well without any tweaks. Then tightened the aft tank strap, clecoed on the behind-tank angles, tightened the front strap (a very long process w/ numerous breaks). Then the engine-side hose. Pulled it off, put the firesleeve on, saftey-wired that using pliers (don't know where my twister tool is). Put the hose on, then the air filter. Put a little fuel in the tank. Opened the tank valve to fill the filter, tube and hose to the carb. Looks good. Put the xpdr tray back on the lower panel cross beam. Put the lower panel cross beam in place - took a while to get that to fit - it's tight. Put the 6 fasteners onto the cross beam. Secured the center (radio/switch) panel. Secured the RH panel, including the cabin vent air hose, fuel sight tube, and passenger mic/phone jacks. Then to the LH panel. Mixture cable first, then the cabin air vent hose, the static hoses, pitot hoses, the panel itself, then the EIS connectors. Should have done the EIS connectors right after the mixture cable. Then put the sticks back in, then realized all the ground wires were still off the forest of tabs. Squeezed between the sticks and got those back on, then plugged in the headphones and powered it on. Dang! Short in one of the PTT's. Banged an 18" tailpipe extension (auto part) onto the LH exhaust (the one that puts the most soot on the fuselage). Will drill through for a couple of rivets then bring a cutoff disk & the dremel to cut it to length next time. Still need to do FWF items - tank vent, mixture cable, check for leaks, fix PTT, then back to flying.
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Installed fuel tube arrangement.
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New hose with fire shield.
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New hose in place. Fits nice.
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