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Thread: Building the EX3 - Tips & Hints

  1. #151
    Senior Member stede52's Avatar
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    Default Re: Building the EX3 - Tips & Hints

    Quote Originally Posted by Daveembry View Post
    I guess Mitch doesn't want them on the public forum since it's suppose to be only for builders so just email Mitch for the links.

    Thanks, please send them to my email at: stede52@comcast.net
    Steve Dentz
    N419LD
    Carnation, WA

  2. #152
    Senior Member stede52's Avatar
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    Default Re: Building the EX3 - Tips & Hints

    Quote Originally Posted by stede52 View Post
    Thanks, please send them to my email at: stede52@comcast.net
    Disregard my email request I'll text Mitch.
    Steve Dentz
    N419LD
    Carnation, WA

  3. #153
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    Default Re: Building the EX3 - Tips & Hints

    CHANGE OF PART FOR THE ELEVATOR BUNGEE CABLE

    Fuse Manual Page 148, FS48 & 49.

    There was a change of part numbers and I can't add this new drawing/figure to the original place in this thread because it will only let 12 attachments/photos per post, so I'll reference that post over to this post to get the figure. I have attached the figure here on this post as well.

    09D3A3A7-B410-4AA3-8FBD-B91AFE0BD711.jpg

    The last kit I got it also looks like THEY CHANGED THE CABLE ASSEMBLY, ELEVATOR BUNGEE TO XC98007-001 FROM THE XC98001-001 AS SHOWN ON FS48 & FS49.

    The new cable has a different connector on 1 end. The end with the loop with be installed per the figures onto the jackscrew end. The other end now has a different type fitting with a notched opening it to slide the end of the spring into and for a screw to secure it. This end will go on the aft side and the spring TC2527-001 will attach to it with an AN23-8 screw, AN960-10L washer; AN320-3 castellated nut and AN380-2-2 cotter pin per the drawing Mitch sent.
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    Dave Embry
    "You only live once.....
    ..but if you do it right.....
    ....once is enough."..

  4. #154
    Member GreggG's Avatar
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    Default Re: Building the EX3 - Tips & Hints

    Quote Originally Posted by Daveembry View Post
    BOOT COWL

    NOTE: I'M ADDING THIS AFTER I HAVE FINISHED THE AIRPLANE AND WANTED TO SUPPLEMENT SOME CHANGES I WOULD MAKE ON THE NEXT PLANE.


    I would take particular note in the EXECUTIVE GLASS MANUAL, Page 24 of the screw locations that hold the ignition box brackets to the fuse. All the bolts/screws used to secure the brackets to each other and to the fuse, I would not use nuts but clipnuts on all the areas so that you can simply unscrew the screws because the nuts are almost impossible to get to when the boot cowl is on. Just imagine you only have access from inside the cockpit through that front panel area and see how hard that would be to do.

    Also, when securing the sensor that the manifold pressure line goes into, I would NOT install it with an Adel clamp on the top, aft ignition box bracket. That is pretty much impossible to ever get back on if you have to remove the boxes. I would install it somewhere else so a simple nutclip can be used on that top, aft bracket screw.
    Do you happen to recall what clipnuts you used?

    Any suggestions as to where to mount the manifold pressure sensor? Will it be obvious when I get to that spot?

    Thanks,
    Gregg
    Carbon Cub EX CCK-1865-0092

  5. #155
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    Default Re: Building the EX3 - Tips & Hints

    Gregg,

    I haven’t done it yet on the current build but will be at that point pretty soon after I get the fuse covered and start wiring. I took off from building for about 3 months this summer.

    I think any clipnut would work that would slip over the bracket and extend for enough for the holes to be centered (much like the clipnuts you use on the backup battery itself in this area).

    The pressure sensor i would mount on the inside of the fuse tubes so that when you remove the right, front, interior panel for access to the ignition boxes and backup batteries, you could also access it from the same location. I’m thinking you could also just zip tie it to one of the tubes instead of the adel clamps.

    Quote Originally Posted by GreggG View Post
    Do you happen to recall what clipnuts you used?

    Any suggestions as to where to mount the manifold pressure sensor? Will it be obvious when I get to that spot?

    Thanks,
    Gregg
    Dave Embry
    "You only live once.....
    ..but if you do it right.....
    ....once is enough."..

  6. #156
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    Default Re: Building the EX3 - Tips & Hints

    Well, someone bitched to me the other day on the phone saying..... "You should have an index to all your posts to make it easier to go back and locate a subject. I'm tired of having to search all the posts to find what I'm looking for!" ...... SOOOOOOO.......

    Note that this thread was done AS I BUILT THE AIRPLANE, so it's in the order of the build. Now there are a couple places where I have done things in advance that makes it easier to do earlier in the build and a couple places where I had to jump ahead while waiting on parts to come in, but otherwise.....if you look in the manual index, this thread pretty much follows it as well.

    I finally got substantially finished this week with a new hangar I was building so ready to get back to work building so I will try and do just that. I'm doing this on the 2nd post of the thread (currently its page 16 but could change as I edit) of this thread and it's a work in progress.

    I have attached this INDEX as a PDF file in this thread that you can download and print if you like.

    I thought I'd go ahead and post what I have for now so you won't have to "work so hard" to find the subject..... LOL.


    INDEX OF POSTS AND SUBJECT IN THIS THREAD

    This is a last minute add-on I added after the thread was finished to help find certain subjects in the thread since different subjects are covered in different posts. 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.

    PAGE 16


    • Post 1 - General Information about the build and the process
    • #2 - TOOL LIST. DRILL BIT SIZES CHARTS
    • #3 - 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


    PAGE 15


    • #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


    PAGE 14


    • #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


    PAGE 13


    • #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


    PAGE 12


    • #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


    PAGE 11


    • #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


    PAGE 10


    • #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


    PAGE 9


    • #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


    PAGE 8


    • #78 - DEFROSTER INSTALL; HEATER BOX; MANIFOLD PRESSURE FITTING
    • #79 - FIREWALL WIRE ROUTING & INSTALLING BOOT COWL; ENGINE MOUNT; INSTRUMENT PANEL VINYL
    • #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


    PAGE 7


    • #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
    • #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


    PAGE 6


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


    PAGE 5


    • #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;


    PAGE 4


    • #122 - AILERONS
    • #123 - FLAPS
    • #124 - SKYLIGHT & TURTLE DECK
    • #125 - GETTING READY FOR THE FSDO OR DAR INSPECTOR
    • #127 - FUEL TANK COVERS; FLAP GAP SEALS


    PAGE 3


    • #128 - SNAP VENTS;
    • #131 - FUEL TESTING; CONNECT PITOT TUBE; AUTOPILOT SERVOS. - PITCH & ROLL
    • #132 - 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


    PAGE 2


    • #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)


    PAGE 1


    • #148 - AUTOPILOT SETTINGS
    • #153 - PART CHANGE NOTIFICATION FOR ELEVATOR BUNGEE CABLE
    Attached Files Attached Files
    Last edited by Daveembry; 09-27-2019 at 10:36 AM.
    Dave Embry
    "You only live once.....
    ..but if you do it right.....
    ....once is enough."..

  7. #157
    Senior Member stede52's Avatar
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    Default Re: Building the EX3 - Tips & Hints

    Dave, you have done a GREAT job of documenting your build, better then any I've seen. Keep up the great work and thanks!!!!!
    Steve Dentz
    N419LD
    Carnation, WA

  8. #158
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    Default Re: Building the EX3 - Tips & Hints

    Glad it’s helping you and others! Makes it more fun hopefully. Thanks.

    Quote Originally Posted by stede52 View Post
    Dave, you have done a GREAT job of documenting your build, better then any I've seen. Keep up the great work and thanks!!!!!
    Dave Embry
    "You only live once.....
    ..but if you do it right.....
    ....once is enough."..

  9. #159
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    Default Re: Building the EX3 - Tips & Hints

    FYI. There is a “Carbon Cub EX Builders” private group on Facebook open only to CC builders. I have been posting videos over there on the fuselage covering and poly fiber install recently. Facebook makes posting videos much easier than here on the forum so check it out if interested.
    Dave Embry
    "You only live once.....
    ..but if you do it right.....
    ....once is enough."..

  10. #160
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    Default Re: Building the EX3 - Tips & Hints

    TOOL LIST ON EXCEL

    Just a note to let you know that if you go back to Post #3 on page 16, I have added an Excel Spreadsheet list of tools used as well as links to where to purchase, cost etc. that builder Jon Hullsiek was kind enough to make and share with me. He added items that were on the Cubcrafters list as well as items I had recommended and some he added. Check it out and download that file if needed.

    PS. Jon said Cleveland would also give a 10% discount for all their items.

    I have also attached it here.
    Attached Files Attached Files
    Last edited by Daveembry; 11-01-2019 at 07:09 AM.
    Dave Embry
    "You only live once.....
    ..but if you do it right.....
    ....once is enough."..

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