Two flights in and I already got really annoyed at building excel charts for my Garmin engine/air logs. I started a new git repository for anyone that wants to work with me here, but it is pretty easy to get from Garmin CSV logs to interactive standardized charts using a little python and the plotly library.
After a lot of back and forth with the FAA/FSDO(s) (months) I was able to finally get an appointment to get N5412K inspected. Yes, it was a lot of paperwork, no doubt about that, but the process was more or less straight forward on my side of it. I think all of the DARs are struggling with the new AWC application system, but that is a different story. I felt fairly well prepared and didn't run into anything that I completely missed. The short of it, N5412K now has an airworthiness certificate.
The one thing to really watch for in this process is the actual text in the Phase II kinds of operation. We had to go back and forth a couple of times with the DAR (the new AWC process) in order to ensure that all of the language was correct in order to get VFR, Night VFR, and Instruments defined in Phase 2 Kinds of Operation. Thanks to the RV10 community for helping me with the exact language to look for.
The process itself was more or less how all of the other blog posts read. Once I was able to find someone that was able to come out, we started the conversation about 30 days prior to the actual inspection. The DAR sent me a checklist of things that he was going to go through and I reciprocated with sending this blog URL with the caveat of "this blog is not actually my build log, I have a real build log."
The process itself was fairly quick. It was more or less a very comprehensive pre-flight (with the inspection covers off) with in-depth inspection into some key areas that I am assuming that either are personal importance to the DAR or pushed down from the FAA. I had two tables with my build logs, the paperwork, the photos, the invoices, etc. We didn't really dig much into each individual entry, but when I scrolled through my photos and electronic build logs the DAR was satisfied that I met those requirements probably purely on the size of the folders. The plane itself had its main root fairings, inspection covers, cowl, baggage bulkhead panel off. For the items of the plane that where not immediately visible I did have photos of every mechanical connection for the things that I did not have access to. For instance I did not have any of the tunnel open or the seats out, but I had photos of every linkage, fuel system fitting, brake system fitting, and electrical connector for anything that was not immediately visible. As a backup I did have an endoscope camera ready to go just incase there was something we wanted to see that I did not have a photo for.
When the DAR sent over the checklist, I did ask a couple of questions and had photos in those questions to make sure things like my ELT antenna placement were going to be acceptable to him. The other common things that everyone else has said/argued I made sure were a non-issue. i.e. Control stick contact with anything, the availability of a Whiskey Compass, etc. The only unexpected thing that happened was the night before the inspection the FSDO asked for the Kit Built checklist. The DAR felt bad about this because everyone knows the RV10 is already on the approved kit list, but we made the decision that fighting it was not worth it, it was easy enough to complete and submit rather than argue.
I performed an initial rigging a couple of months ago when I had to bend the control sticks into a tighter radius in order to clear the panel, but I was always intending to run that one more time right before I buttoned everything up and conducted the final "condition inspection". A post over in the forums led me to the actual location of the flight control limits. The limits are in the "techniques" manual rather than the build manual!
I ended up re-checking with the gauge that the ailerons were neutral at the bell crank and then moved the right wing control rod a turn and a half.
Left Flap (0 degree)
Left Flap (Reflex position)
Right Flap (0 degree)
Right Flap (Reflex Position)
Left Aileron in trail
Left Aileron Up
Left Aileron Down
Right Aileron in trail
Right Aileron Up
Right Aileron Down
Elevator (left side) in trail
Elevator (left side) Down
Elevator (left side) Up
Elevator (right side) in trail
Elevator (right side) Down
Elevator (right side) Up
Pitch Trim (left side) Tab in trail
Pitch Trim (left side) Tab Up
<need to re-take the photo>
Pitch Trim (left side) Tab Down
Pitch Trim (right side) in trail
Pitch Trim (right side) Tab Up
Pitch Trim (right side) Tab Down
With the plane on the scales, the next step was to put the plane into flight level. This line can get picked up at the door sills. Thanks to Jim at the chapter for mentioning to me prior to the start of this that letting the air out of the tires is the preferred approach to get the plane level. That worked well and was way easier than what I had planned in my head for incrementally adding shims under the main tires.
With the plane centered on the scales and centered, it was time to take some measurements. I started my marking out some layout lines and taking the measurements. The datum point in the exemplar W&B from Vans is 99.44 inches forward the wing leading edge. I marked that out and then took the measurements back from the Datum back to the nose wheel and the left and right main wheels.
Something I have been putting off for far too long... When I put my panel in I ended up putting some switches and breakers into the standard location that the Aerosport panel has designed. That looks really nice, but after finally having everything rigged, the control stick would contact the switches prior to the stops in the control surfaces making contact. The internet is very helpful as everyone else that has installed the panel has also had a similar issue. (although it sounds like a lot of people just fly like that)
A lot of the solutions involved heating, bending, cutting, welding. So with all of that, I decided to wait in the process to when I had things close to final rig to ensure I knew exactly how much additional clearance I needed. I also ordered two new control sticks as I was assuming it was going to take a couple of different tries in order to get it where I wanted.
I started with taking my existing control sticks out. I was about to cut them to weld some DOM tube extension but before I went down that path I figured I would just bend them a little to see how things looked. You do not want to bring the stick much more aft as it is already in your lap on full nose up. Also, you don't want to make a bend too low in the stick because (with my short legs) the stick will contact the seat cushion.
With that, I grabbed a pipe bender from the place I most hate (harbor freight) and with the 1/2" mandrel bent the control stick 5 pumps at a time as high as I could. On the first 5 pumps I could see that it was having a significant impact. By the time I got to 10, the control stick with my custom grips was no longer contacting the switches by itself, but with my hand on the stick I could see myself accidentally flipping all of the switches off on a controls pre-flight check. With 15 pumps on the press you can see how much movement I got (and where I got it).
Done.
