Re: Building the EX3 - Tips & Hints
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 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
- #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; ALTERNATOR
- #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 (fuel fittings) ; LANDING LIGHTS, 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 AND CALIBRATION; 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)
- #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
