Page 31-06

May 7th, we got the reed switches in and like everyone else, they didn't work. So, cut about 1/4 inch off the end of the WD-1217 and it worked great. We tested everything using a continuity tester and DID NOT use the test light setup that Van's used.
Page 31-07, routing the wire harness is one of the biggest pains because of the pedal assembly. I've had to run 'lead' copper wires in order to pull the harness wires over the pedals. There's got to be an easier way to do that. I also found that trying to remove the pedals didn't work because the nutplates kept us from pulling the plastic attach blocks out. Then, trying to reinstall them took about 2 hours because of the location of the holes etc.
Page 31-08 was a no problem.
Page 31-09 was ok, just a pain running the wires through the snap bushings and getting our hands inbetween the lightning holes; I'm really glad we smoothed all the edges of the metal, otherwise I'd be all sliced up.
May 9th, we continued on step 8, page 31-09, had to read some of the directions 4 times until I understood what they were talking about. We ran out of female spade connectors; didn't think we'd need to count those in inventory.
Page 31-10 no problems except when it came to installing the jacks for the headsets for pilot and copilot; we had to install xtra washers in order to get them snug on the metal.
PAGE 31-11, George got a couple of bicycle hand grips and got them on after using a little 'personal lubricant' jelly... Installing the 'sticks' were no big deal.
May 12th, Page 31-12 was difficult because we were pushing the capacity of the cushioned clamps and it was a chore running the wires through them. Even though I'm 6'0, I'm double-jointed and that helped running the wires in step 3 around the fuselage frame.
PAGE 31-13 was the tough one I eluded to earlier. Getting the two cushion clamps on inbetween the two rods of the pedal assembly was a nightmare. Most of the work was done by feel, AFTER I disconnected the rudder assembly from the instrument shelf. Ast least that gave me a little more wiggle room. We managed to lose a couple of pins from the wiring harness, so George is going to get some more tomorrow.