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Kurt Haller RV-9A
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Date:  1-1-2018
Number of Hours:  7.00
Manual Reference:  
Brief Description:  Aileron linkages complete; nav/strobe wiring

Backed off the jam nuts on all aileron pushrods and rotated them to the extrema both ways. Pushrods on the right did NOT disengage, as did the main pushrod on the left. But the small pushrod disengaged! It's a tad shorter than it should be.

Added a nylok jam nut to one end of the rod, and filed down a regular nylok to add to the other end. The extra nuts bottom out at the extremes so the push rod CANNOT disengage. After re-rigging, the centered rod has thread at or beyond the bearing witness holes (checked with a feeler wire), so we're good to go.

Checked and torqued (as req'd) and painted all bolted connections along all aileron control linkages, as well as the three pivot bolts on each aileron.

Spent the rest of the day terminating the cable for the nav/strobes on each wing--see images 1 and 2. The green nav/strobe's red power wire broke at the Molex pin--the second crimp wasn't gripping insulation! There were extra male pins so it could be repaired, but I didn't have a pin extractor tool, so I put the red wire in the un-used 5th hole of the connector housing. Now the port and starboard lights are "keyed", Since the long service loop will be flopping about, I'll be adding corrugated plastic split conduit for extra chafing protection. Image 3 is a frame from a short video, taken between coordinated strobe flashes, with the port side taxi light wigging while the starboard side landing light wags.
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Port nav/strobe cable & local gnd

Port nav/strobe cable & local gnd

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Starboard nav/strobe--plenty service loop

Starboard nav/strobe--plenty service loop

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Nav/Strobe and Wig-Wag active!

Nav/Strobe and Wig-Wag active!

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