This year's Annual Inspection
Moderators: Rick, Lance Murray
- Steve
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Re: This year's Annual Inspection
So, the jacks are repaired, and I completed my favorite owner maintenance job - cleaning and repacking the wheel bearings. Emergency battery replaced - 46.2 volts measured at the emergency power switch (it was 46.1 volts measured prior to changing the old Duracells in there). VM-1000 memory chip battery replaced, and engine hours reset:
Now preparing to perform the rear spar reinforcement AD. Removed the carpet in the area, now only have to pull one strip of Velcro off, and mark the location of the patches:
I'll take lots of photos of the process, for those few who haven't yet done this AD. For those select few, you have about 18 months left to do it, depending on how many hours are on your airframe...
Now preparing to perform the rear spar reinforcement AD. Removed the carpet in the area, now only have to pull one strip of Velcro off, and mark the location of the patches:
I'll take lots of photos of the process, for those few who haven't yet done this AD. For those select few, you have about 18 months left to do it, depending on how many hours are on your airframe...
- Rich
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Re: This year's Annual Inspection
I don't know if they've amended the procedure, but when I had the spar AD done a few years ago I farmed it out during the MTOW/MLW upgrade. It called for vacuum-bagging and temperature control. And it wasn't expensive to have it done, as the shop had all the necessary equipment and experience there's and not much labor was involved, given that the rear seat was already out.
2002 DA40-180: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
- Steve
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Re: This year's Annual Inspection
Yes, I have all of the composite gear including vacuum pump and regulator, resin trap, and thermostatically controlled heating blanket for the post-cure. The work instruction doesn't call for vacuum-bagging the repair, but I'm convinced that vacuum-bagging reduces the weight of the repair, so that is what we are doing.
- astaib
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- First Name: Arnaud
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Re: This year's Annual Inspection
When I bought the engine plane, the reinforcement was done already but I spoke with the guy that did it (not at all a mechanic shop), and they didn’t followed the work instruction at all. They did a clean job, but not with the recommended resin, no post curing, no vaccum bag ….
Arnaud
DA40 Star 180 / 40.026 / 2001
Wingtip, landing and taxing LED (Whelen)
Skitube
GNS430 NON-WAAS
Steam gauges
Non certified ADS-b
DA40 Star 180 / 40.026 / 2001
Wingtip, landing and taxing LED (Whelen)
Skitube
GNS430 NON-WAAS
Steam gauges
Non certified ADS-b
- Davestation
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Re: This year's Annual Inspection
Scary! Not sure what clean about that, although as said before vacuum bagging isn’t required.
I think I can top it though, I once saw one where the patches were put on completely sideways!
- Steve
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Re: This year's Annual Inspection
So, today we did the pilot's side spar reinforcement. We didn't do both sides today, because I have only one heating pad to post-cure anyway, so I plan to do the copilot's side tomorrow while we start the post-cure on the pilot's side.
- Steve
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Re: This year's Annual Inspection
More work today. Did the copilot's side spar reinforcement. Started post-curing the pilot's side:
The thin black wire on the left side is the temperature sensor, which is taped to the repair, under the heating pad.
The thin black wire on the left side is the temperature sensor, which is taped to the repair, under the heating pad.
- perossichi
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Re: This year's Annual Inspection
I’m very impressed at forum members who rebuild their own tools including jacks. Soon you will be machining your own fasteners out of bar stock. .
Sold 2002. Powerflo, Hartzell composite two blade, 530W/430, 345 transponder.
- Steve
- 5 Diamonds Member
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- Joined: Thu Aug 12, 2010 1:23 am
- First Name: Steve
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Re: This year's Annual Inspection
Good idea! Would you please convince my wife she needs to find room in our garage for a lathe?perossichi wrote: ↑Sat Jun 19, 2021 10:18 am I’m very impressed at forum members who rebuild their own tools including jacks. Soon you will be machining your own fasteners out of bar stock. .
- Steve
- 5 Diamonds Member
- Posts: 1971
- Joined: Thu Aug 12, 2010 1:23 am
- First Name: Steve
- Aircraft Type: DA40
- Aircraft Registration: N432SC
- Airports: 1T7
- Has thanked: 85 times
- Been thanked: 503 times
Re: This year's Annual Inspection
So, I found another cracked roller, this one was the last original one in the left wing aileron roller assembly (so, almost 20 years old). I had replaced the other two previously, and this last one was the most difficult to work on. For the prior two, I ground the rivet off using a Dremel tool, but for this one there wasn’t enough room to get the tool in there and access the rivet without impinging on the control rod.
I was (just) barely able to slip my hand in there with a small flush-cutting wire cutters and snip the tail of the pull rivet off. Then I forced the rivet out towards the head (lots of skinned knuckles, hand cramps, and cursing).
Getting the old one out is most of the difficult work, installing the new one takes only a few minutes with a hex wrench for the cap screw and a 7mm socket on a small ratchet.
I hope that no more of these crack, since I’ve already replaced the “easy ones”…
Steve
I was (just) barely able to slip my hand in there with a small flush-cutting wire cutters and snip the tail of the pull rivet off. Then I forced the rivet out towards the head (lots of skinned knuckles, hand cramps, and cursing).
Getting the old one out is most of the difficult work, installing the new one takes only a few minutes with a hex wrench for the cap screw and a 7mm socket on a small ratchet.
I hope that no more of these crack, since I’ve already replaced the “easy ones”…
Steve