Hi All -

I've seen a variety of posts inquiring about pre-first flight inspection
items. Some time ago I was in contact with Mike DeHate and asked him what
sorts of things he was finding in the course of flight testing various newly
built Lancairs. He faxed me a list that I retyped. You'll find it below with
minor changes in language. Thanks Mike ..... this is useful.

I can't think of too much to add to all this except to say that what each of
you will be doing is basically a super preflight inspection with the mind
set that you're looking for trouble. You might also think of it as if you
were doing a thorough pre-purchase inspection. I would also highly recommend
that you find one or more other inspectors to review your work. Once you've
looked at something a million times you naturally tend to miss a few things
that you've looked at over and over again.

Ted Stanley - ATP - A&P-IA



From: Mike Dehate

PROBLEMS ENCOUNTERED ON PRE-FLIGHT TEST INSPECTIONS

Rudder pedal return springs too large causing excessive drag and/or friction
on cable

Jamb nuts loose

Brakes weak, spongy, or leaking

Hinge pins need to be safety devices installed

320 models set with flaps reflexing 7 degrees above fillet

Elevator hinges not aligned causing binding

Missing cotter pins

Landing gear "doughnuts" old or soft

Brakes installed with bleeder fitting on top of caliper

Loose cables running thru flap well

Control rod ends without AN970 washers (needs "walls" on both sides)

Bolts too short to extend thru lock nuts

Engine breather hoses kinked

Cabin heat cable bending

Screws loose in gear doors (especially inboard door forward ends)

Fuel tank quick drains without safety devices

Fuel flow transducers not installed correctly

Hydraulic leaks at sequence valves

Cockpits full of trash and building materials

No cooling air for magnetos

Screws loose in carburetor air box (should be saftied to preclude ingestion
into engine)

Fuel gascolator not safety wired

Alternator not safety wired

Engine controls not rigged to give full travel and cushion

Home made fuel lines without clamps (on barbed fittings)

Carburetor air box chaffing on engine cowling

Old hoses and/or fuel lines (brittle)

Excessive gap between rubber engine baffle material and engine cowl

Stiff controls (engine, flight, or otherwise)

Control or flap hinge screws countersunk too deep

Size, height, and shape of engine control knobs identical

Wires to gear switches improperly routed

Gear cycling check not performed after alteration or repair

Insufficient gap at BL50 wing junction

Aileron gap seals too tight (should not touch)

Sequence valve screw loose - jamb nut not tight

Tires rubbing hard on lines in wheel well (perform initial retraction tests
with gear doors removed)

Pitch trim handle too long

Top inboard edge of spars not rounded (cuts like a knife)

Landing gear switch located next to power controls (should be adjacent to
light as far from power controls as possible)

Inboard gear door hinge loose at front attach point

Aileron pushrod rubbing at BL50

Flap actuator rod interference

Tire pressures too high

Engine breather venting into breather compartment

Oil pressure transducer mounted direct to engine

Fuel and oil lines assembled loosely

Packing foam used as an air filter

Safety wire on brake disc missing

Allen head screws holding brake disc not countersunk

Brake Allen head screws not safetied

Cockpit closeout rib not glassed in

Cabin heat valve leaks

NACA vent cutout improperly located (sucks instead of blows)

Bowden cable not secured allowing cable to float

Battery not in box or container

Battery box not sealed or vented to outside

Brakes lock up due to improper rigging

Static system leaks

Prop blades hit spinner dome blade cutouts

Spinner hits engine cowling

Exhaust parts hit engine cowling

Gascolator drains into engine cowl

Hardware missing on landing gear retract system

Controls improperly rigged

Gear does not free fall properly

Landing gear lights tied into landing gear solenoid power

Landing gear doors improperly rigged

Ineffective instrument static system (pitot and static head types)



Hand written notes indicate that center of gravity should be located near
the forward end of the envelope. Another note advises to check the fuel
stand pipe since vent air pressure is critical.

Note that the vast majority of engine stoppages in amateur build aircraft
occur as a result of fuel system problems.