How do you know when you're done?

[LettersFromFlyoverCountry]

I suppose that's a misleading subject since from what I understand, people who build RVs are never done.

In the last few days, i've realized that I'm mostly just puttering on the airplane project -- adding a fiberglass skirt on the side of the canopy frame to hide a bit of the gap, playing with the (&#(&^# rubber strip on the empennage fairing, trying (with kerosene) to get that gunked-on and dried up adhesive off the canopy from the freezer tape I supidly used to protect it four years ago.

There's a few things I need to get done, yet. I need to sand down the SmoothPrime and prime the cowling, but I can't do that until things warm up in the spring, I need to add a blast tube for the magneto, I need to rivet on the forward skin now that everything beneath it is as tidy as I can make it (although that seems like closing the casket cover to me), and I need to install the Flight Line Interiors interior and resecure the heater cable (I don't like the squished S bend connection that Van's recommends). I also need to placard the crud out of the panel.

Oh and I started working on gear leg fairings and almost immediately shoved them back in the box (I don't get it) since I don't need them to be done yet.

There's lots of hardware left so b/c I hate running out of screws and bolts and rivets and platenuts, so that's a lousy indicator.

So, how do I know when it's time to have a DAR look at this thing? Should I wait until all the puttering is done? I used to think I was done when I ran out of money. I was so young and foolish when I started.

[DanH]

Originally Posted by Bob Collins

So, how do I know when it's time to have a DAR look at this thing?

When it is completely ready to fly.

[Mel]

Dan is right. The DAR does not want to see the airplane until it's "complete and ready for flight" with the exception of removal of cowling and inspection covers.

On the other hand, It's NEVER really "done"!

[LettersFromFlyoverCountry]

OK, so if I get the responses correct, the suggestion is "finish all the puttering."

Theoretically, a plane could be ready to fly and still have some things not done that a DAR might "ding," so it's probably best for me just to have everything done until there's nothing left to do.

[flion]

Another way to approach the question is, are you ready to fly it? It doesn't have to be 'complete', but it does have to be ready to fly. Unpainted, no problem. Still working on the wheel pants, but will test fly without and re-weigh when done and painted? Sure, call the DAR. But if it's not ready to go, then hold off. Not just airworthy stuff, either. If you won't fly until it's painted and upholstered, then you should wait to have it inspected.

When you get close to the end, you'll have a pretty good idea when it's all ready to go. I used a condition inspection checklist as a punch list to make sure everything was done. When I only had a few tick marks left and knew pretty much to the day when it would be ready, I scheduled the DAR visit. Oh, and check with the DAR about the condition he expects the plane in. I removed all the cover plates, wing tips, etc. and my DAR arrived and said he expected to see the aircraft ready to go... In fact, you should be talking to the DAR well in advance so you have the program letter all hammered out and he can have the paperwork ready to go upon successful completion of the inspection.

[DanH]

Originally Posted by Bob Collins

Theoretically, a plane could be ready to fly and still have some things not done that a DAR might "ding," .....

No. If a DAR dings anything, the aircraft was not ready to fly.

[LettersFromFlyoverCountry]

Originally Posted by DanH

No. If a DAR dings anything, the aircraft was not ready to fly.

Right, I fully understand that. But that's not really the question. It's based on when I should call the DAR. I have no intention of calling the DAR if I think there's something he's going to "ding"

Like I said, I'll just continue on and putter until there's nothing left to putter on.

[LettersFromFlyoverCountry]

Originally Posted by flion

If you won't fly until it's painted and upholstered, then you should wait to have it inspected.

That's a very helpful answer. thanks.

[hydroguy2]

Bob, I thought 155BK was ready to fly, so scheduled my FSDO guy. It took him a month to make room for me. During this time , is when I went over the plane with a finer tooth comb. I found a couple little things like tiewraps or clamps needing done better. But it was ready to fly....then the FSDO looked it over and told me "NO, it's not ready....no airworthy for you". It took several more weeks to satisfy the Feds.

Now you're probably wondering what did I get dinged on? Paperwork, labeling and misunderstanding between both parties. Stuff I never would have guessed kept me out of the air.
1. engine log did not list AD's complied with for a Lycoming O-360. (mine is experimental with plenty of mods)
2. Static port not labeled.....(who's is?)
3. he wanted the 2" EXPERIMENTAL stencil to be visible from all sides of the aircraft. (mine is only viewable when the canopy is open)

So get the plane and yourself ready to fly....I mean to the point you or your test pilot can sit in it and say yep, wish I had my AW cert, today would have been a nice day for a first flight. BUT, you may still get dinged and delayed.

On a side note, I suspect you are at the point where it feels like you have a broken tie-rod or loose wheel. So have trouble moving forward in controlled fashion. I know I did, several times. What I did was, break the airplane into sections mentally. Grab a clip board and write down what needs done...BUT only on the section you are focused on.

I started at the tail. Go back there and make certain the tail is ready to fly, if not write it down and then FIX it. Don't look at the wings or engine until the tail is ready. Once the tail group is done move to the fuselage (from the tail to the baggage rear bulkhead)..is it ready? if yes close it up and move. Next was the wings. What this did for me was, it kept my focus. I could not move to the engine or the cowl or the wheel pants until the current section was complete.

Good luck sounds like you'll be ready for inspection when it's ready.

[Mel]

Talk with your DAR. Find out just what he/she wants. Maybe even ask for a copy of his/her checklist.
Applying for airworthiness certificate is somewhat like going for your private pilot checkride. If you are ready, it's a skate. If not, you simply re-evaluate, correct the squawks and go again.