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

21st November 2013

Radio Stack Modifications

The VAL COM & NAV radios finally showed up, so this is the current arrangement in the ‘stack’.


Hours: 0.5 | Posted in Avionics | 0 Comments

20th November 2013

Cleanup for Shifting to wiring, assembly, plumbing

Came out early and spent morning cleaning up work bench and hangar area so I can shift to putting the plane back together.


Nothing like a cleaner area.


Thinking about building a simple jig to let me set up IP, stack, false sub-panel; so I can start on wiring independent of fuselage work. I plan to do all the wiring runs so that they do not go through holes (except firewall and wings)  and the harnesses could be easily laced outside the plane and then transferred over to the plane.

I’m going to build up a fixture using steel angle to represent the forward fuselage section of the longerons, then using the real instrument panel, switch & control panel, mockups of the sub-panel & upper firewall, correctly placed & spaced to do the wiring harnesses.

Idea note_20131120_155517_01


This will let me fabricate wiring harnesses, configure & test everything, working independently from fuselage work.




Hours: 7.0 | Posted in HANGAR, Tools | 0 Comments

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

14th November 2013

More firewall

Trying to finish up firewall:

Grounding block, firewall forward



Grounding block, firewall aft.



I decided to have a backing plate and nutplates for the RDAC-XF. The layout has holes for AN3 mounting bolts into nutplates (4) and a number of rivet holes for attaching the backing plate. Fabricated the backing plate.



And primed the backing plate for attachment tomorrow.


Hours: 4.0 | Posted in Uncategorized | 0 Comments