I knew what was wrong with the two LED annunciator light problems, even before looking. They were easily fixed with new DPST locking switches, allowing proper wiring logic. Once in hand, they still took a couple hours to install. It took about 5-6 hours to get at the ARINC 429 interface unit, but I finally did manage to conquer its serial communication problem with a new, fully shielded connection to the EFIS.

However, the problems with the Ray Allen LED trim indicators persists. I thought the elevator trim issue was resolved, but no. As for the flap position indicator, the potentiometer in the linear actuator delivers position data to the Aircraft Extras controller just fine, but for reasons still unknown, the controller needs something different to produce position indicator output. That's peculiar, but at some point, I'll figure it out. Meanwhile, at least I can begin buttoning up at least the side sections of the panel again.

Working on the panel has reminded me I am still missing one essential avionics system. Actually, it was Garry W. who reminded me of this glaring (but invisible) omission. Just in time too.

So... in addition to continued work on the wing fairings, after 14 (!) months of procrastination, I've finally been digging into and conquering the final punchlist of things that need fixing and resolving behind the panel. [No pictures here, nothing to see except panel guts hanging out again.] After spending most of a year building the panel, the prospect of tearing into it had become hugely onerous in my imagination long ago. Completion of this task has been hiding up in the "Before Engine Start" section of the task list spreadsheet all that time. None of these things affects airworthiness, but all should be fixed.

Four of five items I've now diagnosed rather easily, as I suspected I would. Two LED lights that were ON when they should be OFF due to simple wiring errors -- working too fast to finish back then, I expect. Flap and elevator trim position indicators not working -- one a loose connection, and the other a fairly straightforward calibration issue. I've also replaced the ELT remote's internal battery that was set to expire in December, but is now good for another four years, and re-routed a short piece of the static plumbing.

All that's left to figure out now is why the ARINC 429 interface box isn't talking to the AFS EFIS. And so far, it looks like this will, as I feared, require getting at the ARINC box itself, which is perhaps the most inaccessible item crammed into the very tight, panel-challenged Rebel's avionics innards. Getting to it is going to require pulling several parts of the panel apart. When I built the panel, I knew the ARINC box would be hard to get to if I ever had to. The time has come -- sooner than I expected. Not fun, but it probably won't be as bad as I've imagined it will be for the last 14 months. After all, I do have passable notes about the disassembly sequences required, which are complex.

Nevertheless, at this point, having gotten up close and personal with all the wiring again, and having conquered the other things on the punch list, I'm actually looking forward to just getting it done, whatever it takes. I really have no choice, because it's the last thing standing in the way of re-installing the rudder & brake pedals, re-installing the control column, building the control cables, and... in short, the one thing that can't be put off any longer.

Let the surgery continue. Scalpel, please.

Work began on the wing root fairings today. After thinking it through, it seemed easier to start with the leading edge wrap around piece. At this point it and the top strip have been cut, located, drilled and trimmed. Fortunately, it's turning out to be easier than expected. The leading edge wrap around piece shown below was first made in poster board, before transfering the shape to metal.

A number of adjustments were necessary to the windshield retainers. The two side retainers required 1/8" shims to make the angle of the screw heads to the retainer acceptable. The shims also tended to rock the retainers forward a bit, improving the grip on the windshield. The top retainer was widened so the screws could be put through the center flat section. That required extending the paint on the roof further back, etc. At some point the rivets in the front retainer will also be painted white. However, other than that, it's finally, really, completely done! Yea! Also completed was the mounting bracket for the AFS secondary GPS puck antenna, seen just under the left eyebrow skylight (picture right). Little by little, step by step, progress happens.

Finally, the windshield got installed today, but only after much cogitation and obsessing about every detail of the process by me, plus due deliberation by neighbor Mike, who lent a steady hand and more than one good idea, and Miggles' quick shutter finger on the camera to preserve the evidence. The whole story, with all ten pictures deemed worthy of publication, deserves and got its own article page. Following are a couple of highlights. As seen in the first photo, the first dicey part was placing the windshield itself, with the sticky butyl rubber sealant tape already stuck on the back of the side and top edges. If it touched the wrong surfaces at the wrong times, we would have had a major league mess. We lucked out.

After intervening steps (see the whole story) the next critical stage was putting the fiberglass retainer in place on top of the gooy bedding and glazing compound, while gingerly maneuvering it with the sticky black butyl tape sealant on the windshield side. (Mike was occasionally dubious, but calm.) We got it lined up without smearing the sticky stuff... much.

Even with some goo squishing out on all sides (as it was supposed to) when the special large flange rivets were finally all pulled down tight, the "60-hour retainer" is looking sleek. 

The end result, a clear and clean windshield installation. Really clear! Yes, there's a windshield there.

The whole story, or as much as can be told, with more photos, is here. There are still a few small details to finish, like filling in the gaps around the upper corners, but compared to the last three months of work focused on this task... that's miniature peanuts.

The end is getting closer. Going forward from here, there are still decisions that will have to be made, and parts that will have to be built more than once, but the last of the big mystery "I have no clue how this is going to work" tasks is almost done.

Still waiting for a special order of large head rivets to install the windshield retainer. I did pull the protective film off today, however, and was relieved to find it came off easily and cleanly. A number of builders who have had their windshields sitting around for so long (14+ years for this one) have found getting the stuff off is not easy. Anyway, it's sitting here, guarded by the orange safety cones, so I'm less likely to kick it by accident. It's beautiful, and so clear that I took a picture of it and, were it not for a few reflections, it would hardly be visible. (Those are loose fibers and dust, not scratches, on the near edge.)

In the meantime, I've finally started digging into the punch list of final items to resolve under the panel. The remaining 4-5 issues are small and not critical to operations, but I want to fix up details nonetheless. It's daunting to get under there again, staring up at the more-or-less organized forest of wires. Overwhelming to remember what it took to get them there, but I can't put off tying up these few loose ends any longer. I'm hoping that pulling and tweaking a few things here and there won't be nearly as arduous as it was to design and build the whole thing in the first place. It'll be good to have the last little things done, so I can reinstall the rudder & brake pedals and finish those systems. After that... engine start. Oh yeah.

Final trimming and sanding of the prop spinner backing plate was finished yesterday, the prop was re-torqued to 130 in./lbs., and the spinner is ready for final fairing and prime painting. Today, after the usual laborious masking process, the inside ceiling "under windshield" area was painted. That section was painted now, because masking the eyebrow skylights after the windshield is installed could be problematic. The windshield retainer has been painted with white UV-protective primer, looks great, and is ready to go. The large flange [head] rivets ordered last week should arrive tomorrow or the next day. The only other remaining task before windshield installation is removal of the protective coating. Absent unforeseen snafus, the windshield should by installed by Thursday. It feels like a lot of things are starting to come together. Yea!

The cylinder baffles needed two additional tiny spring retainer brackets each to hold the springs which attach to stainless safety wire wrapped around the two forward cylinders on each side. As shown in the first photo, they are made from 1/2" angle. As seen in the second photo, after additional sanding, Scotchbrite™ buffing, and alodining, they were riveted to the baffles.

At last, the fiberglass windshield retainer is finally ready for paint. Doesn't look like much has happened since the last photo, but many hours have been added since then, including trimming and shaping the ends to interface with the metal side retainers, adjusting final thicknesses along the whole length, detail fills here and there, and on and on. It's hard to believe that so far, I have more than 60 hours invested in making this one part. When the paint work is done, sometime next week, the windshield will finally get installed, and there will be some serious celebration.