Sunday, April 17, 2016

A giant to-do list

I got a bit too much sun yesterday working in the back yard, so today was less sun and more list-making.  After taking apart Goat and putting it away, I flipped through the drawings page by page and tried to mark everything there is left to do.  Too many things... so here are a few pictures to lessen the length of the list.





Open questions:
  • Do the aileron control rods need quick links?  They were very awkward while attached to the wing during dis/assembly...
  • How to get the ailerons to fold flatter against the wing upper surface?
  • Why aren't the cabanes folding flatter against the bottom of the wing?
  • Aft, lower strut attachment bracket holes are twisted?  Re-make the nose carry-thru tube and match drill?
  • Check cabane aft tubes ... why did I buy replacements last big order?
 Buy list: 
  • small shock cord
  • 3/4" washers (3x needed) for the flap control flanges
  • 1/8" quick links (1x flap, 2x aileron linkage)
  • (4x) AN3-4 for hinges
  • (4x) AN3-5 for hinges
  • (4x) AN3-5A for aileron turn pullies
  • (2x) AN3-24A for root area
  • (2x) 3/8" x 0.035" x 20 for tip aft upper brace
  • find a better seat and then actually attach it
To Do list:
  • bolt lengths and cotter pins on cabane to wing attachments
  • install bolts on aileron turning pulley (done left, not done right)
  • install correct length bolts on both aileron pulley brackets
  • swage aft cables (4x remaining)
  • fiberglass the ribs to LE and TE
  • leading edge shell (G4S9)
  • glass wrap on aileron control tube guides (4x total)
  • correct length bolts both aileron and flap hinges (there is an AN3-6 in place of an AN3-4)
  • correct bolts for horizontal tail strut lower attachments (G4T19)
  • glass the ailerons and right flap ribs
  • hard-points for the flap control flanges
  • DONE move left aileron control line to below the cross-brace cable at the root area
  • rivet aileron crank tube to trailing edge (G4S4)
  • flip aft aileron control horn bolt to other direction
  • flip side of flap panel flange and bolt directions (see G4S10)
  • aileron crank tube slot
  • aileron crank tube plates enlarge holes and deburr so the stainless part don't rub a sharp edge
  • stiffener for aileron control line
  • trim nose skid tube to length
  • make a nose skid (G4N10)
  • check if the control stick axis bolt has a cotter pin
  • check if rudder pedal hinges have cotter pins
  • confirm there is a sleeve in the nose tube lower attachment
  • sidewalls in forward nose section (G4N13)
  • round off the tail skid to be more roundy than pointy
  • threadlock on every quick-link
  • AN3-26A bolt into the forward line guide bracket, replacing a rivet (G4T14)
  • attach snap hook on elevator control arm with shock cord
  • neoprene eyebolt spacer: horizontal stab (G4T8), elevator control arm (G4T16), tail strut (G4T19)
  • wrap every pulley with tape and heat shrink to hold stiff and straight
  • cabane compression braces (some are loose after the cabane rework from G3 to G4 design)
  • check every quick pin for elastic retainers are both present and correct length (several are just singles)
Post-covering to-do:
  • inspection panels
  • velcro to hold ailerons & flaps up for storage
  • gap seals
  • tow-hook release pin, line, guides, and handle (G4N17)
  • emergency parachute (G4N19)
  • fairings for main struts, jury struts, and tail struts

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