Inspection!

Thank you to Steve for coming over to give a pre-covering (well, pre-wing-covering) inspection.  In short, my Goat passed with only one must-fix item - an aileron control line ran over a cable and rubbed when it should have gone under and cleared.  I also have a few pages of minor fixes and inspection points...

In case it matters to readers, Steve is an A&P, has built multiple homebuilt aircraft (including one named Hot Grand Champion at Sun 'n Fun), is a multi-time national champion flying pattern RC aircraft, worked on jets as a service member, and has made a career in aviation.  He's qualified.

We did an assembly of Goat together, walking through the process and looking at each joint when inserting the pin.  (recently I adjusted the length of the jury struts, so it actually went together nicely)  He then walked around slowly and looked at practically every joint and connection and cable.  Steve found many small things, like a missing washer or bolts that were too short.  He also looked at the big picture, such as noticing a slight bow in the leading edge tube.  This was really thorough!

Here's the full list:

• DONE right forward aileron cable goes under, not over --- SAFETY CONCERN
• DONE switch one washer over to the bolt head in the rudder pedals
• DONE left wing trailing edge cable is not tight
• DONE flip upper bolts behind seat
• DONE trailing edge root bolts are short, and don't match the right side
• DONE turn around cabane aft upper bolts
• DONE neoprene spacer G4T8
• DONE neoprene spacer G4T16
• DONE neoprene spacer G4T19 (2x)
• DONE lower tail flying wire needs to be bent a little more out, in line with the cable
• DONE put kink in elevator covering stiffener (worked like a charm!)
• DONE tail flying wires chafe the flap bolt head - twist bolt so the cable doesn't rub
• DONE radius tube on the end of aileron torque tube, because it can rub the nose covering
• REMOVED elevator cotter pins were wrong method of folding
• DONE add reinforcement patch/tape where elevator control bolt rubs fabric (inside tail)
• DONE (5x) add reinforcement patch on horizontal stabilizer bolt heads
• DONE add inspection ring for the elevator linkage
• DONE add reinforcement patch inside the nose covering that could get rubbed by the ailerons
• DONE mark nuts with torque seal
• DONE add friction tape (cloth, not plastic) to cable crossings that rub
• DONE G4N7 - AN3-26 drilled for the torque tube in pitch direction
• SKIPPED G4N11 - AN3-14 drilled for torque tube in roll -- added torque seal instead
• DONE put liquid electrical tape on the control cable ends where I forgot heat-shrink
• DONE G4S13 - aileron line stiffener (1/4" x 0.035" x 10" tube)
• install leather patch guides for elevator control lines
• replace the nose tube (because the holes are twisted)

Items to do as part of the wing covering

• DONE make foam pads for the lower surface wing ribs to support the fabric
• DONE add/check all cotter pins
• SKIPPED trailing edge AN42B hits fabric (where?) -- shorten?
• DONE add inspection ring for the aileron linkages
• DONE add inspection ring for the aileron pullies
• DONE make sheet metal stiffener for the aileron linkage
• add leather patch to wing tips where will rub the ground

List that includes buying things:

• BOUGHT add friction tape (cloth, not plastic) for cable crossings
• BOUGHT put liquid electrical tape on the control cable ends where I forgot heat-shrink
• BOUGHT replace the nose tube because the holes are twisted
• BOUGHT use torque seal to mark bolts
• BOUGHT leather patch for elevator cable on the covering
• BOUGHT leather patch for wing tip where it will rub the dirt
• BOUGHT G4N7 - AN3-26 drilled for the torque tube in pitch direction
• BOUGHT G4N11 - AN3-14 drilled for torque tube in roll
• BOUGHT G4S13 - aileron line stiffener (1/4" x 0.035" x 10" tube) 
• BOUGHT find/make draw-string baggie for protecting the control cables during transport (2x)
• SKIPPING possible treadless tire option (to save weight)

Assembly Inspection and Annual Inspection

• left wing aileron line needs to go below the cable (must catch during assembly)
• metal-to-metal contact at each quick-link in the elevator control (in the nose), in the aileron control (in the wings)
• use tri-lube (or other recommended) to lubricate the Harken pullies

Since Goat was fully assembled, here's a nice shot of the current progress.  Looks much nicer with both ailerons covered, and the covered cabanes add some visual solidity.  It'll soon be really different with the wing panels covered too!

Here is the offending safety issue.  You are looking at the right wing, toward the leading edge from behind, and looking at the aileron pulley sending a control line toward the root.  The rope going over the steel structural cable is the issue, since the cable would eventually saw through the rope.