Return-Path: Sender: (Marvin Kaye) To: lml@lancaironline.net Date: Tue, 30 Dec 2003 13:00:05 -0500 Message-ID: X-Original-Return-Path: Received: from mail.indian-creek.net ([209.176.40.9] verified) by logan.com (CommuniGate Pro SMTP 4.1.8) with ESMTP id 2910906 for lml@lancaironline.net; Tue, 30 Dec 2003 12:08:41 -0500 Received: from pavilion (sl40.du.indian-creek.net [209.176.40.56] toucan@78055.com) by mail.indian-creek.net with SMTP (IOA-IPAD 4.0) id 02YW800 for ; Tue, 30 Dec 2003 11:09:53 -0600 X-Original-Message-ID: <003101c3cef7$c2537840$3828b0d1@pavilion> From: "Jim Cameron" X-Original-To: "Lancair Mailing List" Subject: Legacy Build Order X-Original-Date: Tue, 30 Dec 2003 11:09:53 -0600 MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_002E_01C3CEC5.7366C520" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: Microsoft Outlook Express 5.00.2615.200 X-MimeOLE: Produced By Microsoft MimeOLE V5.00.2615.200 This is a multi-part message in MIME format. ------=_NextPart_000_002E_01C3CEC5.7366C520 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Based on maybe 90% completion of my Legacy, here are some thoughts = about what order to do things: -- Try to get everything in place that runs through the center = console before actually bonding it in place. I spent two weeks in the = builders' workshop in Redmond, where we fitted the center console and = ground the slot for the flap torque tube. Come to find out later that I = had to re-do all of that because we had not put in the seat belt support = bracket, or the fuel pump mount, or a few other things that change how = the center console fits. [You'll also need to do a flox release on the = aft side of the center console so the bearing block for flap actuator = tube will sit flat.] You particularly want to get the hydraulic lines = in place that run up over the spar and toward the front of the center = console. After bonding the console in place, it's almost impossible to = get at any of that. I suggest getting everything fitted and trimmed, = then holding the center console in place with Cleco's for as long as = possible. -- As with all of the planes, don't put the windows in until the = very last. You'll find you'll need to get into the baggage area a = zillion times before you're through. -- Try to do all of the body work on the bottom before you come off = the rotisserie (you do have a rotisserie, right?). I actually went = ahead and finished all the painting, leaving join lines at body edges, = as much as possible. I'll have some extra work feathering the paint = where the early and late paint jobs meet, but it sure beats doing all = that body work, painting, and sanding upside down underneath the = airplane. Even if you're not doing your own painting, at least do the = body work and have it ready to paint. -- Think about wire routing before bonding the center console in = place. There isn't much provision for this in the Legacy, so you need = to think carefully about how wires will come from back to front. About = the only way is through the thin area in the center of the spar that is = already cut out for the flap motor pushrod. You can make some holes = here and fit grommets, which, again, will be a lot easier before the = center console is bonded in place. You have battery cables, antenna = cables, ELT stuff, autopilot servo cables, plus wiring for the gear = motor, overhead console, etc., etc., and it all has to come through this = small area. Make the holes and grommets big enough, and align them so = they don't hit the flap torque tube. -- Before bonding the center tunnel in the baggage compartment in = place, make some more holes in the bulkhead at the rear of the baggage = area for wiring. Much easier before bonding in the tunnel. (I know, = because I didn't do them until later.) -- Put the fuel lines in place in the wing as early as possible. = After all the gear stuff gets in there, it gets much harder. = Incidentally, I'd think about replacing all the -8 fittings and 1/2" = tube with -6 fittings and 3/8" tube. The 3/8" tube worked fine on two = ES's; the intake fitting on the fuel pump of the IO-550 is a -6 fitting. = Plenty big enough, and easier to work with. For that matter, if = Crawford only made a little more variety of bulkhead fittings in = Swagelok, I'd get rid of all the AN flare fittings and substitute = Swagelok. (They don't make bulkhead elbows, either in 90- or = 45-degree.) Happy building! Jim Cameron Legacy, N121J reserved ------=_NextPart_000_002E_01C3CEC5.7366C520 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable
    Based on = maybe 90%=20 completion of my Legacy, here are some thoughts about what order to do=20 things:
 
    --  Try to = get=20 everything in place that runs through the center console before actually = bonding=20 it in place.  I spent two weeks in the builders' workshop in = Redmond, where=20 we fitted the center console and ground the slot for the = flap torque=20 tube.  Come to find out later that I had to re-do all of that = because we=20 had not put in the seat belt support bracket, or the fuel pump mount, or = a few=20 other things that change how the center console fits.  [You'll also = need to=20 do a flox release on the aft side of the center console so the bearing = block for=20 flap actuator tube will sit flat.]  You particularly want to get = the=20 hydraulic lines in place that run up over the spar and toward the front = of the=20 center console.  After bonding the console in place, it's almost = impossible=20 to get at any of that.  I suggest getting everything fitted and = trimmed,=20 then holding the center console in place with Cleco's for as long as=20 possible.
 
    --  As with = all of the=20 planes, don't put the windows in until the very last.  You'll find = you'll=20 need to get into the baggage area a zillion times before you're=20 through.
 
    --  Try to = do all of=20 the body work on the bottom before you come off the rotisserie (you do = have a=20 rotisserie, right?).  I actually went ahead and finished all the = painting,=20 leaving join lines at body edges, as much as possible.  I'll have = some=20 extra work feathering the paint where the early and late paint jobs = meet, but it=20 sure beats doing all that body work, painting, and sanding upside down=20 underneath the airplane.  Even if you're not doing your own = painting, at=20 least do the body work and have it ready to paint.
 
    -- Think about = wire routing=20 before bonding the center console in place.  There isn't much = provision for=20 this in the Legacy, so you need to think carefully about how wires will = come=20 from back to front.  About the only way is through the thin = area in=20 the center of the spar that is already cut out for the flap motor = pushrod. =20 You can make some holes here and fit grommets, which, again, will be a = lot=20 easier before the center console is bonded in place.  You have = battery=20 cables, antenna cables, ELT stuff, autopilot servo cables, plus wiring = for the=20 gear motor, overhead console, etc., etc., and it all has to come through = this=20 small area.  Make the holes and grommets big enough, and align them = so they=20 don't hit the flap torque tube.
 
    --  Before = bonding the=20 center tunnel in the baggage compartment in place, make some more holes = in the=20 bulkhead at the rear of the baggage area for wiring.  Much easier = before=20 bonding in the tunnel.  (I know, because I didn't do them until=20 later.)
 
    -- Put the fuel = lines in=20 place in the wing as early as possible.  After all the gear stuff = gets in=20 there, it gets much harder.  Incidentally, I'd think about = replacing all=20 the -8 fittings and 1/2" tube with -6 fittings and 3/8" tube.  The = 3/8"=20 tube worked fine on two ES's; the intake fitting on the fuel pump of the = IO-550=20 is a -6 fitting.  Plenty big enough, and easier to work with.  = For=20 that matter, if Crawford only made a little more variety of bulkhead = fittings in=20 Swagelok, I'd get rid of all the AN flare fittings and substitute=20 Swagelok.  (They don't make bulkhead elbows, either in 90- or=20 45-degree.)
 
    Happy=20 building!
 
Jim Cameron
Legacy, N121J reserved
 
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