1. N1605A RV-9A
The building of a dream

2. Preamble Why the RV-9A Speed Mission Reliability & Builder support
Maintenance and modification
Modern
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3. Empennage 3/26/2013 Picked up Empennage kit
Met Jeff Bloomquist (RV-7A) and Harry Nelson (Harmon Rocket) on this day
Purchased my first "Airplane" tool. A pneumatic rivet squeezer from Jeff.
5/2/2013 first Tech Counselor visit by Brian Lee
Lessons learned:
Dimples really are the key to a good looking rivet job
Prep for primer is important to a good priming job. (acid etch and scotchbrite)
Take your time and do it right…pay attention to the plans, not just the narrative.
Buying a tool kit designed for building RV's will save you lots of time!
Customizations
VS top fairing installed with hinge to make it removable for future camera mount
Internal rudder stop
LED Nav/Strobe on rudder
Time to build (minus finishing details): 2 months

4. Wings 5/16/2013 Picked up my wing kit (slow build) Lessons Learned
Proseal is not as bad as they say! Its just not fun.
Jigs make the job easier
Van's takes you off of the "bottle" at this point and they expect you will know things like "debur after you drill a hole".
There are a LOT of rivet holes in the wings….
I need a paint/priming booth
Center consoles consume a ton of time…especially when you don’t use them
Make sure all wing root wires and hoses are installed and tight before you bolt the wings on permanently
Customizations
Leading edge lights installed (not by Van's plans)
Custom locking fuel caps. BEST OPTION EVER!
Conduit installed in wing for wiring runs.
Wing tips installed with hinge instead of screws.
Archer VOR antenna installed in wing tip (fiberglassed in)
Roll AP servo mount installed
Installed bung port in outboard side of fuel tanks in case I ever decided to install extended range tanks in the wings.
Aileron stops using Delran plastic instead of aluminum angle.
Time to build: 4 months minus finishing details (lower skins, wing tips, wiring)

5. Fuselage 8/20/2013 Picked up kit. (slow build)
Second Tech counselor visit by Brian 2/14/2014
Lessons learned:
You have to engage your brain with this kit…
Rivet buddies are worth their weight in gold
DRDT2 should be mandatory
Get the biggest "forest of tabs" you can…you're going to need it if you go all glass.
Keep the wiring as simple as you can… especially under the seat pans
Customizations
AntiSplat Aero VS bracket brace
AntiSplat Aero "Almost a 14 mod" Love it!
SafeAir pitot static kit (with static ports)
Classic Aero Seats/Glare Shield Trim and Carpeting (highly recommended)
Baggage compartment floor openings for ADSB and transponder install.
Reinforced passenger step to hopefully eliminate cracking issue
Flush rivets on step mounts
Affordable Panels modular panel system with Carbon fiber panels (Mark and I made the carbon fiber stuff, this kit comes with aluminum)
SteinAir aluminum vents (highly recommend that aftermarket vents be used. Van's leak badly)
Two cooling fans installed in top skin inside cockpit to aid in cooling and act as defroster

6. Fuselage - Continued Customizations Time to build: 6 months+-
Stainless braided hoses for all fuel and brake lines.
Parking brake
Wing root control rod air boots
Two access panels installed in top skin outside of cabin for easy access to wiring and for installation of GPS antenna's. (fiberglass covers) Works well.
Vertical Power VPX for power distribution
Removable passenger stick (push button release)
Various lighting modifications
Multiple Ram mounts for IPad/drink holder/phone…etc.
Tosten Stick grips (pilot grip has full functionality, copilot has none)
Rudder petal extensions for pilot side. Should be mandatory mod
Rheostat controlled heater shutter
Time to build: 6 months+-

7. Finishing Kit Picked up kit 2/14/2014 Lessons learned: Customizations
Cutting the canopy was just as nerve racking as they say but using Silkaflex made it less so
Fiberglass work is fun…sanding isn't
Sam James plenum isn't worth the money. Build your own.
There is no "easy" way to fill pinholes
Customizations
Slider "Tip Up Mod" (still not complete)
SilkaFlex for canopy work
Carbon fiber and fiberglass canopy skirt
Carbon fiber canopy lift loop
Sam James cowl and plenum
AntiSplat Aero Nose Job 2 for nose gear support
AntiSplat Aero wheel bearing modification. Installed pressed in sealed bearings so no bearing grease packing required. Also had the wheels/tires balance and rounded.
Kroger Sun screen

8. Firewall Forward Lessons learned: Customizations
This one is all on you…not much help from Van's (because of the variety)
IO-360 is a great engine for the 9A!
Mufflers…probably not worth the cost
Red Cube (fuel flow totalizer)…. Saga continues
Fuel Injection is not great for hot idle
Shielding the fuel lines from exhaust is very important
Customizations
Taper pin for nose gear
Firewall mounted 9 row oil cooler with 4" ducting
LiFePo battery ok but too light. I need weight up front
Stainless braided hoses and steel fittings used for all fuel system lines and fittings
PMags for electronic ignition
Rheostat controlled oil cooler flapper valve
Lycon Ported and flow balanced all 4 new cylinders
AntiSplat Aero Air/Oil Seperator
Custom oil cooler ducting

9. Making it an Airplane Final Inspections First Flight (March 2, 2015)
4 different people did a final inspection and each found something that could be fixed or modified
Follow the EAA guidelines to the letter!
Charlie Cotton is the nicest guy you will meet and perfect for the FAA inspection
The FAA inspection was the easiest part
First Flight (March 2, 2015)
Nerve wracking to say the least
Heavy left wing
Engine running very rich
Fouled all four bottom plugs
Had to go around on first landing attempt

10. The final product Van's RV-9A Slider N1605A
Empty weight: 1059
Gross weight: 1800
Useful load: 741 lbs.
Fuel capacity 36 gallons
Engine: Lycoming IO-360 M1B EXP
Forward facing horizontal induction (Superior)
Bendix fuel injection
Dual PMags with auto plugs
Vetterman "Trombone" exhaust with mufflers (sort of)
Catto 3 blade carbon composite prop with 4" Tillman extension
Avionics
Garmin G3X Touch
Single 10" display
Single ADAHRs
GTX-23 ES Remote Transponder Mode S
GDL-39R remote ADSB
GTR-255 Nav/Comm
GTR-20 remote comm
GPS-400W approach certified GPS
GMA-240 audio panel
GMC-305 autopilot controller
GAD29 IFR adapter

11. The final product Avionics Continued Performance Future
GRT Mini-X backup EFIS with remote magnetometer and OAT probe
EICommander Pmag monitor
406 ELT
Electronic CO2 monitor
IBBS backup battery for G3X display, ADAHRS, EIS
Performance
Top Speed…unknown but its above 200 mph (209 VNE)
Stall clean: 49 knots
Stall in landing config: 43 knots
Cruise: 150 knots burning 8 gph
Range…unknown but I do know its bladder limited
Ceiling: supposed to be 24,500' but I've only had it up to 14,000' with lots of climb left in it.
Future
Paint or vinyl wrap
Finish interior. Need more cockpit storage and insulation…its gets cold above 10,000'!
Replace landing lights with LED
backup alternator
Finish tip up mod and include stop points for taxi with canopy partially open
Time to Build: 23 months (no idea how many hours...lots....)