Title: Nose Lift
This is a 2-part entry. First, the work done in 2009 by the original builder, then the 2021 work I have done. 2009-07-02 (5.00 hours): I know it doesn't seem like a big step, or something that should have taken this long. But today I installed the switch for the Wilhelmson nose gear lift. Several years back, when I purchased this unit, I also bought the AEX1 auto-extension module. I quickly came to hate it - every time I turned on the power, it wanted to extend the gear, and nearly caused several accidents in the build process because of that. And I didn't like the standard answer of adding a breaker or switch - what good is a safety device that you can disable? This also came with a big rats-nest of wires, some of which didn't even match the supplied wiring diagram. For instance, "white" for me was actually grey. Blue was purple. It took a while to wire, and it looked like a mess. I never did get it neatened up to my satisfaction. Today I cut all the wires out of the rats nest, removed the AEX1, and rewired the unit with the bare minimum of wires. I kept everything neat, bundled all wire bundles together with heat shrink tubing, and now I have a clean and simple installation that I'm finally happy with! The only thing I have left to do is replace the LED grommets - they're just sort of sitting there right now. I need deeper grommets for my instrument panel. I'll address all the LEDs at once when I do the full panel setup later. Besides, I'd just have to remove them anyway when I do my panel overlay (which I may do with carbon fiber trim sheets off eBay. 9/12/2021. I also found a rat's nest of wires, and no functioning auto extension. I built an auto extension unit following the schematic posted by Marc Zeitlin (attached) and removed the wiring of the prior install. I constructed the unit as a panel-mounted module, and located it below the SDS ignition controller, then remade it to have the switches and transit lights in my switch panel, assorted relays on a remote mounted tray. Wilhelmson guidance says the lift is fused at 10 a, and the wire sizing guides say that the installed power leads (18 AWG) are wildly redundant: good to 30 amps over the 3 foot distance. But other builders have found that a fully fueled Cozy with 2 large passengers puts a significant load on the Wilhelmson nose lift. One builder went with a 15a breaker and 14 AWG wire, and believes this is beneficial. I will move ahead with the current installation and then revise if appropriate. The Zeitling Auto Landing Gear Extension uses 2 relays of 2 circuits each and one relay of 3 circuits. In addition there are 2 pitot pressure activated switches, a throttle position switch and a LIDAR (light detection and ranging) unit to sense AGL altitude. In operation, the unit will auto extend when there are 3 simultaneous conditions: air speed of 40-90 knots, throttle less than 10% and less than 280 feet (85m) AGL. The unit has a disarm switch protected by a safety switch cover. Attached are the LIDAR install manual and the settings I programmed in. This was a challenging bit of kit to assemble and then install. I started with some basics - I learned to label each of the circuits on the several relays, noting common, normally open and normally closed. I made aggressive use of shrink tubing to strain-relieve the numerous joins, and liberal use of solder sleeves rather than a ring terminal setup. The WIlhelmson unit connects to the panel through a 9-pin Molex using the high power .093" pins (rated to 17 amps per pin). After the ease of DB9 pins the Molex is particularly awful to work with, and I had to find the tools to rebuild the harness. I ended up going with individual connections under shrink tubing, as in the Nuckolls method for DB9 pins in small spaces. Finally, I found and used a lot of (Mil Spec) zip ties to organize a challenging set of wires. The gear lift itself is protected by a cover which is easily removable for service, with wires passing through rubber grommets. One build note - the Wilhelmson nose lift was installed without use of a violet wire in the #1 position: a white 22 AWG was used in its place. I have marked the pin numbers and confirmed the function of each - otherwise the unit is consistent with the technical guide provided by Wilhelmson's EZ-Lift. 1/18/2024 The Wilhelmson design is the best available for the Cozy, but it had a design flaw addressed by a retrofit kit. See the attached write-up.


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