Gremlins galore

 Nose gear high resistance connection. Found a bare ground splice under a wiring label in the wiring harness.

Capacitive fuel tank levels.   Reading high.  Corrected by tightening ring terminal screws on hell hole ground strip.

Hall Effect amp sensor occasionally reading negative instead of positive.  Cross checked with the VPX. -Update - seems to be working after tightening ring terminal screws. 

High fuel pressure.  Reseated the connector at the sensor and treated with LPS1 (electrical contact lubricant).

Flat nose tire.  Tire balancing beads had gotten in the valve stem seal when I checked pressure.  Cleaned out with a Q-tip and is holding now.

Red X's on CHT's & EGT's -  Remedied by tightening the ground on the engine.  The jam nut and nut were tight, but retightened and issue cleared.

#2 Spark Plug cap fell off-came unscrewed.  Fell out of bottom cowl when it was removed. -Update - replaced the plugs with solid top plugs.

SDS programmer display  backlight is working, but there's no text displaying.  Update-Barry is sending a new board. Update - board was replaced and is working again.

30 Amp fuse to distribute power for the Landing Gear, B Fuel pump and B coil replaced with a hard wire (each downstream circuit has its own circuit breaker.

Shorted PFD  - RMA'ed to Dynon.   Swapped left/right screens and trouble followed. ETR two weeks. -Update - Panel was returned and functions normally except for the temp widgets intermittently showing X's.  Update - retightened engine ground cable and the red X's cleared.

Pilot relief tube - needs more suck.  Testing with water, didn't draw out.  Need a tube moved into the slip stream to create a vacuum.  Update - tube has been extended.

Nose/leg area - still has a slight draft in flight.  Needs more sealing around the nose gear motor cover.

A quick test flight:  

EZLift Nose gear squawk

 Scenario:

I flew through a little bit of rain en route TX to Nebraska with occasional turbulence.  At the destination airport, the Cozy was parked on its nose in a transient hangar, raised it the nose, moved out of the hangar to load on the ramp.  Put the nose down to make it easier for my wife to get in.  When the gear down switch was moved, it would extend briefly and when the wheel touched the ground it stopped.  The LED by the switch stays lit.  It would retract when switched to "gear up".   Tried again to lower it, same thing even with me assisting.   Wife climbed out and with two lifting on the canard, it raised all the way up when the switch was moved to "gear down".   Initially I thought a low battery was contributing to the issue but the engine cranked right up.  

Since the LED was staying lit, it indicates that at least part of the system had power.  After starting the engine, the system is worked normally again.

I think this particular revision doesn't have high current going through the limit microswitches but will need to verify.   The schematic has a note that "colors may not match".  I think the system had at least two previous owners and the wiring was a rats nest when I got it.  Wires were cut and spliced together.  The AEX P2 plug had one jumper "to nowhere" and a power wire.  It looks like pin 5 should jumper to 6.  With the plug off, the system would not move the gear up, but would move it down.  This opened what would have been the pin 5 to 6 connection.

After parking in my hangar, I've pulled the connectors apart and am not yet finding evidence of a high resistance connections in the plugs.

I do have one of Marc's new actuators and parts minus electronics.  Also have one of Bob Bittner's boards he sold me at RR a few years ago.   I'll work on some other squawks an mull over what to do about this.

-Update 7/17/24 - I found a bare wire splice (3 grounds) that was under a wiring label next to the P1 Molex connector.  I soldered and taped the connection

6/27/2024 Test flight after oil cooler reverse scoop install

No major change, but it seems the oil is a bit cooler.  

Other prep:

Winglet fairings.   (May wait until this winter to do large radius fairings, or make some temporary smaller radius fairings.)

Wheel pant gaps.  (Fill / sanded/ painted)

Ammeter Hall Effect sensor 5 volt check.  (Found a few terminal screws a touch loose.)

Princeton fuel sensors (reading a few gallons high).   Suspect a few loose terminals on the positive buss may be a factor.  Tightened and need to test again.

Found butterfly arm was not up against the stop when WOT.   Repositioned the throttle clamp under the sump to improve throttle travel.

Looked at the K&N filter.  It doesn't have a built in velocity stack like some performance filters do.  The intake OD is 65 mm.   Finding some stacks with screens and some performance filters have built in velocity stacks.