19th November 2013


The firewall is pretty much all prepared, with holes drilled, plate-nuts mounted. As much as I can do until I get the tubes of sealant to start adding things onto the firewall. That may be mostly done after installing the new firewall.



Switched over to forward fuselage as there are a few things to add and/or check out. The ADSB UAT will need both a GPS antenna (upper skin) and a UAT antenna, blade type, floor skins. I want to check on cable runs & lengths to make sure everything is OK. Also want to start on the forward section fuel, vent, and brake plumbing.



Removed everything that could be removed in preparation for final cleanup, painting and plumbing required in forward fuselage section.



There are a few last minute changes, additions, deletions. One is the addition of a 2nd small fuse block to support a ‘battery’ bus. That bus is direct to the battery and hot all the time for keep-alives, etc. The 2 fuse blocks will be right above each other as shown here (just taped in place for example). The second fuse block is for the backup bus off of the backup battery.



Then another addition is location of external voltage regulator for the alternator (just keeping my 40A B&C alternator for now). This will be on the opposite side of the sub-panel from the backup battery, using nut plates so that it can be lowered for servicing, if necessary. (Just being held in place here).



Location of voltage regulator with holes drilled.



Another addition is the GPS antenna for the ATSB UAT. I decided to mount this on the upper skin, forward fuselage and just keep it well sealed.



Then the UAT blade antenna is just below on the bottom skin, probably 8 feet from the transponder antenna.




Hours: 7.5 | Posted in Avionics, Bulkheads, Foward Fuselage | 0 Comments

17th November 2013

Sunday Work

I spent some time working on firewall fire&sound insulation plans, and slightly modifying plans for wiring pass thru holes. In addition, to the 2 holes (L&R) already cut, I’m planning a third hole at the far left side of the firewall (below the Slickstart) for the magneto wires. I’m going to route them separately & as far as I can get them from anything audio or digital. The shield of the magneto wires will also be grounded when they go through the firewall.

Also switched to steel fittings everywhere and ordered some 3M Fire Barrier silicone sealant to use on the firewall. Put the one-hole eyeballs up for sale.


Hours: 2.0 | Posted in Bulkheads, Foward Fuselage | 0 Comments

16th November 2013

Quiet Saturday

Stopped at Home Depot for 3/4″ hole plug (nose gear). This one is nickle plated steel until I can find a stainless steel one.

After reading up on in-flight fires and protective measures, I am considering changing the firewall control cable penetration to steel. The wiring feed throughs are already stainless steel. At the very least I decided to reverse the eye balls and then fill the engine side with fire retardant. This helps also with clearance of the items mounted on forward side of firewall.


Hours: 2.5 | Posted in Bulkheads, Foward Fuselage | 0 Comments

15th November 2013

Never-ending Firewall

I decided to cut some lightening holes in the RDAC-XF backing plate.


While that was drying I started on the control cables pass-thrus. Plenty of room for the throttle control cable. Not so for the mixture control cable, so it required some extra work. Also punched 3/4″ hole for nose gear retention bolt. For the eye balls using a 1-1/8 hole punch. The hole punches cut good holes.


The final solution is almost in the RV-7 firewall locations. Still need to do Carb Heat and oil cooler shutter control cables.


Also went ahead and punched 3/4″ holes for the wiring pass-thrus on both sides, left & right, of the firewall. These will use stainless steel hardware to attach an d then fire sleeve and sealant to seal.


Completed the backing plate and went ahead and riveted it on along with 4 nut plates for RDAC-XF mounting. Test fit shown here.


Spent some time getting the forward section prepped & ready for assembly.


Hours: 8.0 | Posted in Bulkheads, Foward Fuselage | 0 Comments

12th November 2013

More Firewall

Final location arrangement of the contactor area, holes drilled ready for mounting:


Brake reservoir, holes drilled, ready for mounting:


Fuel Flow sensor, holes drilled, ready for mounting:


Using the rear side of the firewall to locate the GND tabs, fore & aft.


Just no good way to mount them vertically. Guess I can see why most people end up horizontal above the firewall stiffeners.


OK, I decided, get on with it. Here are the chosen locations for the ground tabs, fore & aft sides of firewall, also the central location for the RDAC-XF, and leaving open the option of a single pressure manifold (if needed) for the manifold pressure between the engine and the RDAC. Actually this side of the engine is the side that needs 2 pressure transucers, oil and manifold. It is the other side that needs only 1, fuel pressure.


OK, think I have made the final firewall decisions and can go ahead and drill & cut the final holes. It’s about 3/4 finished right now and this will let me get to 100%. Decided to keep the option for 2 cabin heat ports after checking the hose fit. After all it is Colorado, not Texas. Decided to have the 2 wire/cable feed thrus directly below the upper skin ribs on each side, put the 2 port pressure manifold on the left, single port on the right (viewing from FWF., and mount the RDAC in the center using nutplates for easy removal, replacement. I have a 2″ knockout punch coming for the cabin heat holes. a 1-1/8″ punch on hand for the control cable feed-thrus, and a 3/4″ punch on hand for the cable feed-thru tubes. Whoops! Better place the holes for all control cable feed-thrus.


Hours: 5.5 | Posted in Bulkheads, Foward Fuselage | 0 Comments

12th November 2013

Yesterdays Work

Went ahead and enlarged the ‘stack’ rectangle in the stack bezel, to one large rectangle, cutting out the metal where the V6 & V20 were going to go.



Decided on just the alternator ANL in close proximity to the main copper buss bar, pointed downwards.



Built a mounting angle for the fuel flow sensor. It will bolt through the firewall and through the brake hose bracket behind the firewall.



As for location for the ground tabs, I want to have a location that puts the through bolt just above the battery negative connection BUT below the upper firewall horizontal angle for access. The main wiring plane is going to be the bottoms of the upper forward skin ribs (same level os the upper angle. Placing it below will give access above the rudder pedals but low enough to reach.


Hours: 5.0 | Posted in Bulkheads, Foward Fuselage | 0 Comments

12th October 2013

Work Catch Up Post

Even though I haven’t been able to post to the server I have been working. These photos will later be annotated to describe work done.

20131010_163406 20130911_144633 20130921_132127 20130921_132147 20130925_154924 20130925_154942 20130925_155005 20130927_111816 20131001_142644 20131001_142654 20131005_154415 20131005_154418 20131007_114043 20131009_123435 20131010_163349 20131010_163349[1] WiringRoutes_01 20131010_163406[1] Challenge 20130619_120302 20130619_122140 20130619_122123 20130619_120302 20130619_120235 20130530_160122 20130530_160148 20130529_140952[1]

Hours: 40 | Posted in Avionics, Bulkheads, Center Section, Electrical, Foward Fuselage, Instruments, Interior, Miscellaneous, Tail Cone | 0 Comments