13th December 2013

Wiring Jig

I am mounting the remaining components into the wiring jig so I can start in earnest on the wiring.

Here are the components mounted to the sub-panel.

Cockpit side: Left is iBox and AFS AOA unit. Right is backup battery and 2 fuse blocks for battery bus, and backup bus.


Forward side, right: Voltage regulator for alternator.


Forward left side is recessed iBox mounting.



Hours: 3.0 | Posted in Avionics, Electrical, Instruments, Miscellaneous | 0 Comments

23rd November 2013

Saturday Work

I only spent enough time at the hangar today to reach a goal of first electrical circuit working before my trip to San Diego to visit my daughter.







Hours: 2.0 | Posted in Avionics, Electrical, Foward Fuselage, Instruments | 0 Comments

22nd November 2013

Forward Fuselage Mockup for wiring

Here is the view from the firewall side. I’m going to just use the old battery from the plane on the wiring fixture, leaving the new battery (PC-680) ready to mount on the firewall.


Spent time finishing up the mock up of forward fuselage to be used as a wiring jig. I’ll do the wiring harnesses here, configure and update the equipment and test pretty much everything. The layout wiring paths, etc. will be done in a way that will let almost everything be transferred over to the plane later. Exceptions will be wires that go through the skins to the wings, some firewall stuff etc.; but the bulk of it can be done much easier here with full access, rather than in the plane.












Hours: 7.0 | Posted in Avionics, Electrical, Instruments | 0 Comments

21st November 2013

Wiring jig

I put the frame of my wiring jig together. It will emulate the upper forward fuselage of the plane and let me do the wiring harnesses, testing, configuration, etc. outside of the plane and independently from the on-going firewall work.

It will use the actual avionics, components, actual instrument panel, but mock up of the sub-panel and upper firewall. I’ll build it all up back to the actual battery and then contactors. Then later everything will be transferred into the plane.




Hours: 3.0 | Posted in Avionics, Electrical, Foward Fuselage, Instruments | 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

19th June 2013

Finally – Some work on the plane

Finally, I have caught up enough on yard, farm, and garden work enough to get to work on the plane again.

The 3 final pieces I had water jet cut were done and I went by to pick them up. The 3 pieces were to finish up the 3 sections of the new instrument panel:

PILOT PANEL – This piece was simply to adapt the current Explorer size (8.5″) display to my cutout for the final Challenger display (10.4″)

Fit OK but lesson learned is don’t trust the manufacturer drawings to be correct.



STACK BEZEL – The stack ended up being a mix of stack type avioinics, small round radios, some I/O connectors for new electronics, and some custom lighting controls and AOA at the top. I made a bezel to mount & space everything correctly.


I made an error on entry here in the height of the audio panel. It is 1.3″ versus 1.5″, probably just incorrect on entry. I will just space the audio panel on center.

PASSENGER PANEL – This is just the custom built touch monitor bezel with small DVR built in. Only loaded one of the key caps to check for fit.


Hours: 3.0 | Posted in Avionics, Foward Fuselage, Instruments | 0 Comments

30th May 2013

Painting, stack alignment, misc

I have decided to use more dark gray and less light gray. There seems to be something wrong with the light gray or at least I have trouble with it (orange peel regardless of what you do). That’s probably why Home Depot does not stock it. So all brackets, bulkheads, structural elements are going to be the darker gray and I will look for a new light gray.

I masked & prepped the cockpit side rails & canopy mating surface and painted them the darker gray, also a few small pieces that will be used as brackets & holders.



Also spent some time looking at flush alignment of the stack. I’d like all the facing surfaces to be flush with the V6 face surface. This is a real odd ball stack, from short to long, all in one stack.


Dropped a sheet of 2′x 4′ 6061-T4 0.063 aluminum off at the water jet place. 3 Week estimated but then I could be filing for 3 weeks with those cut-outs. Need to get my own milling system.


Side View of the long & the short of it!


Removed masking tape & paper.




Hours: 6.0 | Posted in Avionics, Foward Fuselage, Instruments | 0 Comments

29th May 2013

IP Back apart, mounting stuff on the sub-panel

Took the instrument panel out of the way, while mounting things on the sub-panel.



Repaired Display covers before shipping SL-40 display board to Brother for display chip replacement.


Hours: 4.0 | Posted in Avionics, Foward Fuselage, Instruments | 0 Comments

28th May 2013

Last Water-Jet Pieces

I decided on some key-caps for the small monitor keyboard and finished the drawing for the last 3 small panel pieces for waterjet cutting.


Hours: 2.0 | Posted in Avionics, Foward Fuselage, Instruments | 0 Comments

23rd May 2013

Small Water Jet Jobs

I spent some time in AutoCAD getting drawings ready for 3 small water jet jobs:

1. Pilot panel plate just to adapt Explorer display to Challenger cut-out; however Challenger is supposed to be released at the end of July (2 months off).

2. Passenger side – bezel for the right side monitor I’m building.

3. Center stack bezels to space everything correctly & hold it in place, along with extra buttons, switches, I/O  for computer, AOA, and annunciator/lighting controller.

Here is the drawing for the center stack bezel to give you an idea:


Hours: 4.0 | Posted in Avionics, Foward Fuselage, Instruments | 0 Comments