Wednesday, August 29, 2018

Section: avionics
Hours: 3

I started work on installing the GEA 24 sensor wiring harnesses. I pulled all the wires through the left firewall through hole, but now I believe it might be better to route the wires for the right side of the engine through the firewall through hole on the right side...


Monday, August 27, 2018

Section: avionics
Hours: 3

I installed the FlyLeds controller board under the pilot seat and connected it to the wiring harness.



Thursday, August 23, 2018

Section: avionics
Hours: 6

I finally have all the parts in hand for assembling the electrical system tying the alternators to ships power system. One shunt came with the firewall forward kit from Vans, but since I am installing a backup alternator, I had to order another shunt, fuse and fuse holder.

I am going to place the fuses and shunts on the motor side of the firewall close to the battery contractor. I laid out the bolt holes on an aluminum plate that will hold all the parts.

Then I fabricated copper buss connectors to tie the shunts to the fuse holders and to tie the fuse holders to the electrical system. The lead from each alternator will connect to the shunt for that alternator.

Here is the assembly with the fuses installed.


Wednesday, August 22, 2018

Section: 50
Hours: 2

I installed the co-pilot cabin heat cable.


Tuesday, August 21, 2018

Section: 49
Hours: .5

I riveted the oil cooler air inlet assembly together.

Section: 50
Hours: 3

I installed the cabin heat cable on the pilot's side. I decided to replace the cables that come with Van's fire wall forward kit with cables that have a pushbutton lock. Some previous builders had recommended this so that you can firmly hold the heat doors closed during the summer.

I trimmed the cable to the correct length with the dremmel tool. Then spent quality time under the panel installing the adell clamps and connecting the cable to the heat flap lever arm.



Heres the cabin heat cable with the push button lock installed in the control panel.

Section: avionics
Hours: 1

I decided to replace the cigarette lighter with a dual USB charger. There are a lot of these chargers available on Amazon, but the one I got was a little more expensive but supposedly does not radiate a bunch of electrical noise and won't interfere with the radios and intercom.




Monday, August 20, 2018

Section: 49
Hours: 4

I prepped and primed parts for the oil cooler inlet assembly.

Friday, August 17, 2018

Section: avionics
Hours: 4

I'm planning out how to place the shunts for the primary and secondary alternators. I ordered from Amazon some small inline fuses and fuse holders and a couple mounts for the shunts. I also purchased some brass bar and copper sheet from the the Lowes.


Wednesday, August 15, 2018

Section: avionics
Hours: 3

I connected the cabin wiring harness to the flap actuator.


Tuesday, August 14, 2018

Section:
Hours: 4

Proseal day! I added a fillet of pro seal to the top of the instrument sub panel.

Then I glued the air vents in place. The trick here was using just the right amount of pro seal for a good bond without too much squeeze out.


Monday, August 13, 2018

Section: 38
Hours: 5

I painted a top coat of epoxy on the air vents, a couple of the cabin floor panels and the cabin rear closure panel.

Saturday, August 11, 2018

Section: 41
Hours: 6

The weather is good and I have a just enough primer left to finish the wing root covers and stiffeners and the prop spinner bulkhead.

Friday, August 10, 2018

Section: avionics
Hours: 3

I installed the mounting tray for the ELT and wired up the connector and antenna.


Sunday, July 29, 2018

Section: avionics
Hours: 5

I fabricated a harness for connecting the FlyLeds controller board to the left and right wing.
 I will run the yellow wire to one of the grounding tabs on the panel. Power will be picked up from the cabin wiring harness.

Friday, July 20, 2018

Section: 47
Hours: 2

The snorkel is supposed to be aligned with the fuel injection servo. Then you match drill the snorkel flange to the fuel injection servo flange. I fabricated an aluminum jig with a circular wood plug the size of the snorkel inlet to aid with alignment.

Here the jig is duct taped to the field injector servo. When I mount the snorkel, it will automatically center on the jig.


Wednesday, July 18, 2018

Section: avionics
Hours: 4

I worked on the wing wiring harnesses and started working out how to connect the FlyLeds (white coax) and pitot heater (red/black twisted pair) wiring.

Left wing root:

Right wing root:


Tuesday, July 17, 2018

Section: avionics
Hours: 5

I tried running the cabin wiring with the elevator and control stick pushrods in place, but there just wasn't enough room. Unfortunately, the wiring end connectors are already attached and it is impossible to squeeze them through the central tunnel when the push rods are in place. It was a hard job putting these push rods in place and it was equally hard removing them. I'm sure it will be difficult to put them back in after the wiring is done :-(

The wiring going to the wing will have to be modified to attach to the FlyLeds...

Section: avionics
Hours: 3

Started laying out the cabin wiring harness. Stein provided the Van's standard cabin harness along with the rest of my panel. It connects to the panel harness with 2 large connectors up front. It will require some modification to work with the FlyLeds strobe and nav light system...


Friday, July 13, 2018

Section: avionics
Hours: 8

I routed and connected some of the wiring harness today. Here is the starting point. The harness is located behind the sub panel with individual cables threaded forward to their appropriate boxes.

Here I've attached cables to the pilot's side of the panel going to the GEA 24 and the panel switches.





Here is the co-pilot side with cables for VPX, dimmers, etc. I ended up mounting the circuit board with the dimmer circuits towards the top of the center bay side wall. None of the ground wires in the big bundle of black wires are labeled! Bummer, I'll have to sort those and label them.

The coiled wire bundle has wires for smoke pump, cabin lights and some other things I'm not sure about. Stein provided a generic schematic of how wires run between connectors to the various avionics boxes, but not a drawing of the actual harness that was built. I will have to contact Stein to find out what the mystery wires are for.

Here is a view from the top center.

Beginning to look like a panel!