I am weeks away from Final Inspection from my local DAR.  I was wondering
what to expect.  Did they make you put the plane on tests for retract tests?
  Leave it retracted overnight to test for leaks?  All cotter pins installed,
safety wire, etc?  Basically, it has to be in flight ready condition, right?
  So I should do it at the airport, not outside of my garage?  Will they do
taxi tests?  Fuel tests?  What other tests do they or could they do?
 
  Basically, I just wanted to seek input from others as to how their
inspections went and how long it took.  I know it all depends on the
individual DAR but just wanted to be ready.

Matt,

 

Why don't you call the DAR before he comes out and ask these questions of him/her.  They aren't out to get you.......

 

You will have to start the engine.

 

You must have your paper work in order - ARROW minus the first AR.  That is, Registration, POH (um, maybe - incomplete is ok) and W&B.  Also, your builder's log, pictures and anything else that helps assure the DAR that you built more than half of the airframe.

 

The DAR will ask you "builder" questions and if there is uncertainty in some construction area, it will be probed further.

 

Remember, the DAR comes with your airworthiness certificate filled out - do the right things and he will leave it with you plus, perhaps, a short list of items to complete and log before the first flight.

 

You should/could have already done taxi tests, avionics checkouts and, of course, static air and transponder checks - well, at least before the first flight.  So, take it out to the airport soon.

 

I remember when the FAA inspector asked me for a piece of safety wire to check the witness hole in a few rod-ends.  All was ok (the wire wouldn't pass thru) and later that night, just before dropping off to sleep, I visualized all 40 rod ends - and I saw that they were correctly fastened with lock nuts torqued down in place.

 

Later, when the test pilot was examining the airplane, I bet him $50 he would not find a discrepancy.  He immediately reached behind the aft spar and fondled the castle nut securing the flap push rod main bell crank, noting that the cotter pin was missing.  As I passed him the picture of Grant, he said that it was the most common builder oversight.  Which brings up another point - have others that built your model take a look at it before the first flight if you can.

 

Good Luck - I am looking forward to another Lancair crowding my sky...