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.

ALSO, I have a YouTube channel with over 60 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
  • #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 -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 - 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
  • #161 - Updated wiring chart spreadsheet
  • #162 - List of EX3 data such as consumables (oil, plugs, grease, oil, etc) and G3X Settings and Manual locations
  • #163 - Connecting the front stick#wiring to the harness
  • #164 - 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)
  • #177 - Adjusting the Acme Stinger Tailwheel
  • #187 - Link to many Youtube videos of installation of many EX3 parts