<Archive Thread> Building the EX3 - Tips & Hints

[ceslaw]

Jake:

Yes indeed.

What's crazy is how much I forgot from our builds - what was it - six or seven years ago?

EX3 looks like a lot of plane.

Chuck

[Daveembry]

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

[Daveembry]

Recently when looking through some old files, I ran across my original invoices where I made most of my initial tool purchases. I made a pdf of them and have attached them here as well as over in post #3 where I talk about the tools, etc. https://forum.cubcrafters.com/showth...ll=1#post21578

I get many questions about what to get and where to get it, so thought I'd put it out there. Also attached at that post is the Excel spreadsheet which lists tools, costs, etc. That Jon Hullsiek did for us.

I'm not sure if Cleveland tool is still in business or not, but much came from them, some from Aircraft Spruce and some from Amazon. If you know the tools you need, most can be purchased from Amazon as well. (and cheap stuff from Harbor Freight).

If you come across something in the manual you need but don't have (like LETTER drill bits, etc), Amazon is usually the quickest place to get them with Prime shipping.

[PBY Catalina]

...

I'm not sure if Cleveland tool is still in business or not, but much came from them, ...

The last time I ordered something from Cleveland Tool was in July 2020.
They have been excellent in all aspects with me, even if the delivery was to be made on the other side of the Atlantic!
Good products, good support, fast delivery...
Really to recommend!

Yves

[Daveembry]

Here is a new video I did showing how to set up the paint color lines and stripes for the Cubcrafters standard Signature Plus paint scheme.



https://youtu.be/U8dlT95FgDU

[Daveembry]

WIRING CHANGES TO THE STANDARD EXECUTIVE GLASS WIRING

This panel has the G5 (backup attitude), GAD29, GNC355 (Navigator); GMA245R (audio panel); GTR20R COM Radio and GTX245R Transponder along with the other standard avionics.

I just finished up installing my first “IFR” panel and added both a video and written instructions on the changes from the standard harness connections and considerations. I added the comments over in post #72 where I discuss the wiring connections. So go to this post to see the details

https://forum.cubcrafters.com/showth...ll=1#post22470

the video is here in YouTube:

https://youtu.be/VrK5BXHUmyQ

[Daveembry]

Just a note to say that I've uploaded quite a few more videos on the build into my YouTube account. I think there are about 120 right now about the build. The 2 latest ones are:

- Installing the prop on the EX3 https://youtu.be/bDvfEqYffms
- Installing the prop governor https://youtu.be/yGKOTi4Jark

The link to all the videos is https://www.youtube.com/user/daveembry85/videos

[PBY Catalina]

Just a note to say that I've uploaded quite a few more videos on the build into my YouTube account. I think there are about 120 right now about the build. The 2 latest ones are:

- Installing the prop on the EX3 https://youtu.be/bDvfEqYffms
- Installing the prop governor https://youtu.be/yGKOTi4Jark

The link to all the videos is https://www.youtube.com/user/daveembry85/videos

Thank you Dave !
Even if I build an EX2, the vast majority of your videos are very useful to me.

[Daveembry]

HOW MUCH UNUSABLE FUEL IS REALLY IN MY EX3? (a lot more than advertised)

https://youtu.be/1u8okDP7d0Y

Note that this video just shows the actual amount of fuel that remains in the tank in the static, level condition and does not reflect how much fuel will be available to the engine in different flight conditions. (Ie. Hard, climbing turns, etc.)

[Brad Damm]

Dave - Great video and very informative as always! The purpose of building an EAB aircraft is education and recreation, and that is a very educational video on how much fuel can still remain in the system even after the placarded amount of useable fuel has been consumed.

Our designers (and FAA regulations) are conservative, and CubCrafters designs, tests, and placards the aircraft to always ensure that enough fuel remains in the system for the engine to continue making power throughout all phases of flight, including various pitch and roll attitudes other than straight and level.

The FAA’s guidance for amateur builders to determine the amount of unusable fuel on their EAB aircraft is on Page 33 of AC 90-89B, which I have linked below. In part, the guidance is to determine unusable fuel at a pitch attitude 5 degrees above the highest anticipated climb angle that the aircraft can achieve. That same Advisory Circular also offers guidance to amateur builders (on Page 17) as how to calibrate their fuel tank indicators. We recommend that amateur builders follow that guidance when building or testing any CubCrafters kit aircraft.

https://www.faa.gov/documentLibrary/media/Advisory_Circular/AC_90-89B.pdf

I know you said it in the video, but to emphasize in case anyone out there missed it; it is not safe to run any CubCrafters aircraft down to 1.4 gallons of fuel remaining in the system. At any fuel amount that is less than what is placarded as useable, the aircraft operator is at risk of a loss of power due to fuel starvation.