<Archive Thread> Building the EX3 - Tips & Hints

**PBY Catalina** · 06-08-2022, 05:23 AM

Originally Posted by Daveembry

Yes, depending on when you got your kit (serial number), there could be more or less missing parts. Pete and CC has done a great job on updating the manuals and packing lists (Bill of Materials) on the most recent kits. My last kit was serial number 94 and it was much improved. I’ve been updating this forum thread on each build to keep it updated with the latest manuals and materials.

The engineering on these airplanes is simply amazing. Everything fits and flies great!

I have to say that I’ve already been very upset and wasted a lot of time because of inventory errors, parts supplied that don’t match my orders, manual errors, etc. But I recognize that the parts are of good quality and that CC, Pete in particular, does everything to correct these errors. We must also recognize that we have all had a difficult period to pass and that transport between the USA and the EU is becoming, and this is a shame, more difficult than with China!
Luckily, the CC builder community is vibrant. You saved me valuable time! Especially you, Dave. When I neglect reading your texts or videos, I always end up regretting it! I plan to come to the USA soon, to visit CC and come to greet some of you.

**Daveembry** · 06-08-2022, 05:43 AM

Thanks Yves. It makes it all worthwhile when I hear it helps others out!

I actually do the same thing…….I skip along building and then go back and read my own post and realized I missed something! I try and make myself review my relevant posts or video before doing the next step.

Originally Posted by PBY Catalina

I have to say that I’ve already been very upset and wasted a lot of time because of inventory errors, parts supplied that don’t match my orders, manual errors, etc. But I recognize that the parts are of good quality and that CC, Pete in particular, does everything to correct these errors. We must also recognize that we have all had a difficult period to pass and that transport between the USA and the EU is becoming, and this is a shame, more difficult than with China!
Luckily, the CC builder community is vibrant. You saved me valuable time! Especially you, Dave. When I neglect reading your texts or videos, I always end up regretting it! I plan to come to the USA soon, to visit CC and come to greet some of you.

**Daveembry** · 06-22-2022, 04:02 PM

INDEX OF POSTS AND SUBJECT IN THIS THREAD

Generally, I have followed the order of the build in the thread......in other words.....I wrote this thread as I actually built the airplane. Most of the time you will notice it pretty much follows the order of the manual but in many instances, I have found that doing certain items out of order makes it easier and in a few instances, I had to skip ahead and start other sections while waiting on missing parts to be delivered.

ALSO, I have a YouTube channel with over 120 videos showing how I did many of the more difficult areas.

https://www.youtube.com/user/daveembry85/videos

Post 1 - General Information about the build and the process
#2 - TOOL LIST. DRILL BIT SIZES CHARTS
#3 - TOOL LIST ATTACHMENT; WING BUILD START; ORGANIZING PARTS & INVENTORYING; ROTATOR INFO
#4 - WING BUILD/DIAGONAL TUBES; MAKING "DOUBLE RIBS"; SPAR ATTACH FITTINGS
#5 - DRAG WIRES; MACHINED RIBS
#6 - NOSE RIB PREP; TRAMMELING THE WING
#7 - REAR SPAR REINFORCEMENT; PULLEY BRACKET
#8 - TAIL RIBS; MACHINED CLIPS

#9 - NOSE RIBS; CAPSTRIP ON #5 DOUBLE RIB
#10 - CAPSTRIP ON #1 & #3 DOUBLE RIBS; BOTTOM CAPSTRIP ON #1 DOUBLE RIB
#11 - #3 RIB BRACING; #2 FALSE RIB; FLAP FALSE SPAR INSTALL; AILERON FALSE SPAR; AILERON HANGAR BRACKETS
#12 - AILERON FALSE SPAR more detailed. WING WIRING
#13 - PITOT TUBE TUBING; LANDING LIGHTS; RIB FAIRLEADS; LEADING EDGE SKIN PREP
#14 - OUTBOARD RIB AND CROSS BRACE (Jump to post #22 to finish leading edge skins and wing)
#15 - MAGNETOMETER BRACKET AND WIRING IN RIGHT WING
#18 - CAPSTRIP PART NUMBERS LISTED FOR RIGHT WING

#19 - COVER; TAILFEATHER COVERING; GENERAL RECOMMENDATIONS ABOUT OVERING, USING POLY TAK AND POLY BRUSH; ELEVATOR COVER; STABILIZER COVER

#20 - STABILIZER COVER FINISH
#21 - COVER - RUDDER
#22 - LEADING EDGE SKINS INSTALLED
#23 - LEADING EDGE SKINS FINISHED; LANDING LIGHT LENS HOLDER
#24 - WING TIP BOW; NUTPLATES AROUND FUEL TANK
#25 - FUEL TANKS
#26 - PULLEYS & CABLES; FUEL TANK GROUND WIRES; RIB SPACER BLOCKS; ADDITIONAL HOLES FOR FABRIC; HARDWARE ON CABLE ENDS - Shackles

#27 - COVERING THE WINGS (PREP & COVER)
#28 - SUMMARY OF COVERING THE WING
#29 - TAPES; GROMMETS & FABRIC PATCHES ON WING; LANDING LIGHT DETAIL

#31 - WING TAPES & PATCHES & RIVETS; TIPS ON USING POLYBRUSH ON TAPES
#33 - POLY FIBER TIPS ON MIXING AND USING BRUSH & SPRAY
#37 - PUTTING FUSE ON BOGERT ROTATOR; FUSE INSPECTION; BRAKE LINE CONNECTORS FOR STAINLESS STEEL LINES; PEDALS & TORQUE TUBE INSTALL; FUEL SELECTOR ASSEMBLY; FLOORBOARD INSTALL; REAM FUSE HOLES; INSTALL UNDER SEAT PARTS IN ADVANCE

#38 - BOTTOM PULLEYS & CABLES; EXTENDED BAGGAGE PANELS & DOOR

#39 - EXTENDED BAGGAGE DOOR ASSEMBLY INSTALLATION

#40 - REAR SEAT CABLE INSTALL; RUDDER CABLE FAIRLEADS; ELT ANTENNA INSTALLATION; ELEVATOR CABLE FAIRLEAD BLOCKS; FUEL LOW POINT DRAIN
#43 - THROTTLE QUADRANTS
#44 - STRINGERS; SEAT BASE; BATTERY BOX; TORQUE TUBE INSTALL; CONTROL STICK STUBS; AILERON STOP PLATE
#45 - HEATER DUCT; RUDDER/BRAKE PEDALS; INSTALL FLOORBOARD
#46 - PEDAL SPRNGS; PULLEYS & CABLES; SEAT BELT SCREW HOLES
#47 - FUEL LINES

#48 - FUEL LINES CONTINUED

#49 - VERTICAL FIN; ELEVATOR TRIM COMPONENTS
#50 - TRIM MOTOR INSTALL; SIDE FABRIC SPACERS
#51 - INTERIOR PANELS; ADDING POCKETS
#53 - MAP POCKETS
#54 - INTERIOR PANELS FITTING
#55 - RUDDER CABLES
#58 - TRIM MOTOR INSTALL & TEST; BODY FILLER

#59 - BOOT COWL BUILD PART 1

#60 - BOOT COWL BUILD PART 2
#61 - FUSELAGE FINISHING UP FOR COVER; COVERING FUSE PREP
#62 - FUSE COVERING
#63 - TAIL FEATHER COVERING; HOW TO ADD BRUSH AROUND RIVETS
#64 - MY POSITIVE PRESSURE PAINT BOOTH
#65 - COVERING ELEVATORS; PREPPING FOR ELEVATOR TRIM TABS
#68 - FLAP HANDLE ASSEMBLY

#70 - WIRING G3X TOUCH; INSTALL FLAP HANDLE; DOOR HEADER PANELS; SOLENOIDS; INSTRUMENT PANEL

#71 - WIRING CHART I MADE; CONNECTING WIRES
#72 - WIRING CONT.
#73 - WIRING - SETTING UP AND TESTING THE SYSTEM
#74 - AUTOPILOT SERVO INSTALLATION - ROLL SERVO
#75 - AUTOPILOT SERVO INSTALLATION - PITCH SERVO
#76 - PREP BELLY PAN FOR SCREWS; THROTTLE & PROP CABLES; TAILWHEEL INSTALL; 3X3 GEAR INSTALL
#77 - SEAT BELTS; BOOT COWL; FIREWALL CABLES & WIRES; FUEL PUMP; GASOLATOR

#78 - DEFROSTER INSTALL; HEATER BOX; MANIFOLD PRESSURE FITTING

#79 - FIREWALL WIRE ROUTING & INSTALLING BOOT COWL; ENGINE MOUNT; INSTRUMENT PANEL VINYL; CONNECTING FUEL LINES TO GASOLATOR AND LOW POINT DRAIN

#80 - FIREWALL POPULATING WITH PARTS AND WIRES
#81 - ENGINE INSTALL - PRE-INSTALL ITEMS
#82 - ENGINE INSTALL CONTINUED. INSTALL ENGINE TO MOUNT
#83 - ENGINE INSTALL - COMPLETING INSTALL
#84 - ENGINE INSTALL - THROTTLE BRACKET; ALTERNATE NOICE FILTER; OIL PRESSURE ADJUSTMENT; PROP GOVERNOR INSTALL; BAFFLES;
#85 - ENGINE INSTALL - CHT PROBES; BAFFLES (CONT); OIL COOLER; GROUND WIRE ATTACH; SNIFFLE VALVE; BAFFLE SEALS
#88 - STARTER WIRE; SIDE DOOR; IGNITION SENSORS; MIXTURE CABLE; THROTTLE CABLE; FIREWALL HOLE SEALING; FUEL PUMP DRAIN HOSE; EXHAUST PIPES

#89 - HEAT MUFFS; ALT AIR ATTACHMENT; EGT PROBES; BAFFLE SAFETY WIRE; IGNITION COIL MINI-SENSOR ADJUSTED

#90 - PROP INSTALL
#91 - ENGINE COWL
#92 - ENGINE COWL CONT.; OIL DOOR
#93 - DOOR HANDLES; EXPERIMENTAL STICKER; STATIC PRESSURE LINES; HEATER BOX/DEFROSTER HOSES; REAR BAGGAGE CARPET; WHEEL TORQUE PLATES; INSTALL EXTENDED BAGGAGE DOOR
#94 - BRAKE LINES; INTERIOR PANELS; PLACARDS; D WINDOWS; FLAP CONES; WINDOW FRAMES; WINDOW LATCHES/CATCHES
#95 - WINDOW FRAMES (CONT); BATTERY BOX; REAR SEAT AND SEAT HOLDER; HORIZONTAL STABS; MOUNTING TIRES ON RIMS; LANDING GEAR INSTALL; GETTING ITEMS NEEDED FOR CERTIFICATION
#103 - PAINTING VORTEX GENERATORS; MAGNETOMETER MOUNTING

#104 - BRAKES & WHEELS; WING PREP; STALL WARNING; VORTEX GENERATORS; TURTLE DECK RIVETS
#105 -RUDDER & ELEVATOR TRIM TABS; WING & RUDDER LIGHTS; FLYING WIRES; RUDDER CABLE HOLES IN FUSE
#106 - FLYING WIRES (cont.); ELEVATORS
#107 - TIPS FOR ELEVATOR INSTALL BY PETE DOUGHERTY
#108 - MORE TIPS FOR ELEVATOR INSTALL

#109 - ELEVATORS - ADJUSTING; RUDDER & RUDDER CABLES

#110 - WINGS; JURY STRUT I-BOLTS; HARDWARE LIST FOR WINGS & STRUTS
#111 - REGISTERING THE AIRCRAFT WITH FAA
#114 - JURY STRUTS; PITOT TUBE HOSES; FUEL SIGHT GAUGES;
#115 - FLIGHT TESTING
#116 - WINDSHIELD
#117 - WINDSHIELD (cont.); HEADSET HOOKS; AILERON CABLES
#122 – AILERONS
#123 - FLAPS

#124 - SKYLIGHT & TURTLE DECK
#125 - GETTING READY FOR THE FSDO OR DAR INSPECTOR
#127 - FUEL TANK COVERS; FLAP GAP SEALS; OAT PROBE INSTALLATION
#128 - SNAP VENTS
#131 - FUEL TESTING; CONNECT PITOT TUBE; AUTOPILOT SERVOS. - PITCH & ROLL; BELLY PAN INSTALL
#132 - FRONT SEAT INSTALLATION; BEFORE FIRST FLIGHT; BEFORE FIRST ENGINE START; G3X SETUP; FUEL QUANTITY RESET; TRIM POSITION INDICATOR SET; FIRST ENGINE START

#133 - OIL DOOR LATCH
#134 - CONNECT ELT COAX TO ELT; FILLING/BLEEDING BRAKE MASTER CYLINDERS
#135- CHECK FLYWHEEL TIMING RING
#138 - FIRST FLIGHTS - ENGINE OIL; “BEFORE FIRST FLIGHT: DOCUMENT; CHECKLIST BEFORE FIRST FLIGHT; COMPLETE LIST OF ITEMS TO DO BEFORE FLYING
#139 - TESTING & TROUBLESHOOTING; TAPE OFF OIL COOLER; OTHERS ITEMS OF CONCERN
#143 - ALERTS VOLUME ADJUSTMENTS (MINE WAS TOO LOW)

#144- PILOT OPERATING HANDBOOK
#145 - BATTERY TENDER; EAA SEMINAR ON G3X TOUCH LINK
#146 - ALERTS VOLUME ADJUSTMENT FOR THE COM RADIO
#147 - AIRCRAFT MAINTENANCE MANUAL (PDF)
#148 - AUTOPILOT SETTINGS
#153 - PART CHANGE NOTIFICATION FOR ELEVATOR BUNGEE CABLE
#160 - Carbon Cub Tool List on Excel Spreadsheet

#162 - Updated wiring chart spreadsheet
#163 - List of EX3 data such as consumables (oil, plugs, grease, oil, etc) and G3X Settings and Manual locations

#164 - Connecting the front stick#wiring to the harness
#165 - Window Latches on wing
#167 - Testing the magnetometer wiring
#168 - FDGH PPG new paint Mixing instructions and links to PPG Spec Sheets
#171 - Fuel Flow form to measure and document fuel flow for FAA (not required but highly recommende)
#178 - Adjusting the Acme Stinger Tailwheel
#187 - Link to many Youtube videos of installation of many EX3 parts
#190 - 40 amp fuse replacements
#199 - Fuel Selector maintenance/repair
#202 - Index of posts
#206 - Wiring the IFR panel with GNC 355, GMA245R, GTR20R, G5

**aeroaddict** · 06-22-2022, 04:23 PM

Thanks Dave, nicely done. Since you have everything figured out, it makes me want to build another one!!

But I'm to busy flying!! And burning up the kids inheritance for 100LL.

**Daveembry** · 06-22-2022, 04:59 PM

🤣 🤣🤣🤣

Originally Posted by aeroaddict

Thanks Dave, nicely done. Since you have everything figured out, it makes me want to build another one!!

But I'm to busy flying!! And burning up the kids inheritance for 100LL.

**jjoffe@me.com** · 07-31-2022, 06:52 AM

Dave hi
I have tried to access the link to your you tube channel which you have so kindly posted but cannot get there
Thanks again for all your great advice - one thing that I started to do after getting my Left wing started was to build both wings simultaneously and found that to be a huge timesaver I have about 160 hours in and for my first build am already at the Rib # 5 capstrip install (on both wings) which I would love to see on your video.
Best wishes
Julian

**Daveembry** · 07-31-2022, 07:59 AM

Hi Julian,

here is the correct link https://youtube.com/user/daveembry85

Do you recall where you got the link that didn’t work? One of my posts here? If it’s wrong, I will go back in and check it and correct it if it’s wrong. I was just at this link and it’s working fine.

yes, if you’ve got the room, building both at the same time is probably faster since you don’t have to go read the manual, pull parts, etc twice. I build everything at home in my garage until time to put the wings on, so I don’t have the room.

Sounds like you are really making great progress! Congrats.

Originally Posted by jjoffe@me.com

Dave hi
I have tried to access the link to your you tube channel which you have so kindly posted but cannot get there
Thanks again for all your great advice - one thing that I started to do after getting my Left wing started was to build both wings simultaneously and found that to be a huge timesaver I have about 160 hours in and for my first build am already at the Rib # 5 capstrip install (on both wings) which I would love to see on your video.
Best wishes
Julian

**jjoffe@me.com** · 07-31-2022, 01:54 PM

Dave thanks so much
I think it was user error as the other link works fine now.
I know you are a busy guy so sorry to bother you
Best wishes
Julian

**jjoffe@me.com** · 07-31-2022, 02:02 PM

Dave hi
This was the link that has issues
“videos showing how I did many of the more difficult areas.”
https://www.youtube.com/user/daveembry85/videos

I think the www should not be there as that is the difference
Thanks again for your wealth of information
It has really helped me move along with my build
Best
Julian

**jjoffe@me.com** · 08-02-2022, 05:52 AM

Dave Hi, I am unable to squeeze many of the capstrip countersunk rivets on # 5 rib due to space constraint with a couple of different squeezers and planned to use a buck bar with back rivet set - do you modify your rivet squeezer to do these or what do you do or use?
Thanks
Julian

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