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Project: DaveBellairs -
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Categories

Show All Entries - (648)
Research
Workshop - (4)
Empennage - (14)
Fuselage - (54)
Firewall - (78)
Tail Feathers - (40)
Wings - (105)
Controls - (6)
Avionics - (145)
Lighting - (13)
Instrument Panel - (9)
Landing Gear - (4)
Engine - (159)
Propeller - (1)
Fuel System - (7)
Interior Finish - (3)
Paint / Decals - (6)
Inspection
Tools


Builder Name:	Dave Bellairs -

Project:	Vans - RV-7 - VIEW REPORTS
Total Hours:	1452.9
Total Flight Time:
Start/Last Date:	Jun 24, 2017 - No Finish Date
Engine:	Lycoming IO-360
Propeller:	Whirlwind 200RV
Panel:	Advanced Flight Systems Avionics

Friendly URL:	https://eaabuilderslog.org?s=DaveBellairs

Home or Last Project Picture

Apr 23, 2024 Finished stick grips - (3 hours)

Category: Avionics

Marked and drilled the top of the left stick for the anchors holes for the infinity grips. New step drill bit and oil worked well to drill through the steel tubing. Installed grip and routed wires thru the grommet at the bottom of the stick. Reinstalled the left stick and grip in the fuselage and found that my static and antenna lines need to be moved to allow room for the aileron pushrod. One step forward, two steps back. Haha. Installed the right grip on the stick and routed the wires out the hole in the stick and installed the grommet to protect the wires. Reinstalled the right stick and grip in the fuselage. May have cocked the grip a little too far to the left, but that is what felt right.

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Apr 22, 2024 More stick grip work - (3 hours)

Category: Avionics

Sat in the left seat to determine stick height and orientation. Installed the side panel since there is an armrest pad to get a more accurate height. Marked the stick and cut to length. It should be almost exactly the same height as the right. Sat in the right seat and figured out orientation for that grip too. Marked the intersection of the tube and base for removal to the drill press. Taped the cut off portion of the left stick to the base of the right stick since they are the same diameter and used a straight piece of steel to mark the centerline of both sides. Started with a #30 bit and progressed to a bit and reamer fro an AN3 bolt per Vans SB. I may order a button pin fastener from McMaster-Carr to make removal easier. Marked the left stick for holes and slot for the left grip. While I was in the seat, I checked on a location for the parking brake bracket which hopefully won't interfere with my knee.

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Apr 13, 2024 Pilot stick grip - (1 hour)

Category: Avionics

Spent time trying to determine the proper length of the pilot stick and grip orientation on the stick. Need to make sure the orientation is correct since it will not be adjustable after drilling the 7/16” holes for the stick grip. Tried to compare it to the copilot stick, but since it's not removable the lengths will be different to achieve the same height on the cockpit. Tested out my new step drill bit on some scrap tubing and it worked fairly well with some drilling oil. I plan to use a single or double leg spring pin to hold the copilot stick securely in place. As an added plus it came with a new center punch which I needed.

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Apr 10, 2024 Stick grips

Category: Avionics

Finished drilling second hole in copilot stick that is used to secure the Infinity grip. Marked and cut a slot for the wires to pass thru using the stick sleeve as a template. Used my hand grinder to cut the slot and finished up with a sanding drum on my dremel tool. Buffed off the powdercoat with the deburring wheel since the sleeve would not slide on with the powdercoat in place. Installed the copilot stick in weldment in the fuselage and checked for travel. Still interfered with the mixture knob when extended so I'll have to check the aileron travel later to determine if it's a player.

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Apr 09, 2024 Control sticks and grips - (5 hours)

Category: Avionics

Took a break from wiring to work on the stick grips. Marked and drilled both pilot and copilot sticks with 7/16” holes for a grommet where the grip wires will exit. Copilots is above the weldment to make removal easier. Pilot stick has a 7/16” hole in between the elevator weld and the aileron weld. Reasoning being the stick forces are higher for the elevator than the aileron so loss of strength in the stick is minimal. Didn't realize the sticks were different diameters so I don't need two sleeves to make the outer diameter of the stick 1” to fit in my Infinity grips. Pilot stick diameter is already 1” and copilot stick which needs the sleeve is 7/8”. Installed the panel and right seat to check for stick clearance of the panel and engine controls. Also wanted to check for a comfortable stick length. Cut copilot stick to length and had difficulty drilling the upper 29/64” holes for the grip. I think I'm trying to go too fast and the steel hardens. Will try again tomorrow. Also discovered that I mismounted the bracket for the Avidyne navigator so is about 1/2” short to the panel mount. Gonna have to remove the nav metal sleeve and drill out the bracket rivets in the fuse as I've already riveted a large portion of the subpanel in place.

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Apr 08, 2024 Hall sensor and red cube wires - (3 hours)

Category: Avionics

Used some butt splice crimp connectors and heat shrink to connect the hall sensor and red cube wires to the EMS-220 connector wires. Now just need to secure the extra length/service loops to the engine frame along with the engine sensor wires on the right side. Spent some time trying to figure out the mag rpm wires from the drawing. My ElectroAir start switch goes in place of a key switch so gonna need some more info/drawing to wire it up.

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Apr 07, 2024 Hall sensor wires - (1 hour)

Category: Avionics

Pulled the Hall sensor wires back to the firewall along with the orn/wht wire from the EMS-220 connector. I plan to splice these wires into the red cube wires forward of the firewall for easier access. Planning to use a red crimp butt splice unless I can find something better.

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Apr 01, 2024 Shunt wires and red cube wires - (3 hours)

Category: Avionics

Installed the 4-40 ring terminals on the ends of the alternator shunt wires from the EMS-220 harness. Added some heat shrink and installed on the shunt. Installed the OLC-1 connectors on the red cube wires after getting another set screw I lost earlier. There is some debate on the security of these connectors so I added some heat shrink and lacing cord to ensure the connection and strain relief. Rerouted the Hall sensor wire through the right firewall penetration and through the 3/4 snake skin to the EMS-220 connector. Did some research figuring out the connection between the Hall sensor and the EMS-220 wires. Strangely the white/orange wire from the connector connects to the white wire from the sensor and the white/orange wire from the sensor connects to the red wire from the red cube. (See dwg) Meanwhile the blue/white wire from the sensor connects to the black wire from the red cube. Seems like that could have been coordinated a little better. I just twisted the wires together until next work session after I determine the best way to splice the appropriate wires together.

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Mar 25, 2024 More engine sensor wires - (3 hours)

Category: Avionics

Spliced the remaining engine sensor wires to the fuel, oil and manifold pressure wires with heat shrink for support and stain relief. Finished the molex connector for the manifold pressure wires. These molex pins were larger than the ones I've installed before so had to use the “B” portion of the crimpers. Also added a ring terminal for the oil temp sensor wire and connected it to the oil temp sensor. Looked at the mag rpm wires and not sure about where to add the 30k resistors per the drawing and even if they are necessary. Also not sure how to wire up the ElectroAir mag. Gonna check the installation instructions.

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Mar 24, 2024 Unknown wires and Engine sensor ground wires - (2 hours)

Category: Avionics

Used the multimeter to find the pins for the 3 mystery wires. Marked the locations on the connector drawing and secured them to the other wires I don't need. As you can see in photo of the wires in my hand there are 3 ground wires, two aux fuel tank wires and the 3 extra wires. Not sure what to do with the extra wires so I'll give AFS a call for suggestions. Added a molex ground wire to the manifold pressure connector then soldered the fuel, oil and manifold pressure ground wires to the ground wire from the engine sensor connector. Added several pieces of heat shrink to secure the connection and add some strain relief.

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Mar 23, 2024 Engine sensor harness wires - (2 hours)

Category: Avionics

Continued to label the engine sensor wires. Pinned out the 6 ground (black) wires using the multimeter to determine which were which. Also labeled the trim sensor wires that will not be used since I'm using the ACM. Still have 3 wires that don't match the drawing that I'm not sure where they go. Looks like another email to Jonathan at Advanced.

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Mar 14, 2024 EGT/CHT connectors - (3 hours)

Category: Avionics

Installed the remaining EGT/CHT connectors to the SV-EMS-220 harness wires. Used my multimeter to verify the connection of all the connectors to the SV-EMS-220 dsub connector. Added some service loops and may have gone a little overboard, but I can always reduce the extra wire later. Now I just need to clean things up and secure the extra wire.

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Mar 13, 2024 More wire routing and Engine wires - (2.5 hours)

Category: Avionics

Ran the left and right fuel sensor wires from the SV-EMS-220 wire harness out to each wing. The only problem is they only reached as far as the wing spar through the corrugated tubing. White wire taped to the smaller fuel sensor wires is just a pull wire I used to get the fuel wires through the corrugated tubing. Gonna need to splice some wire to get out to the wings. Pulled some of the engine wire back to the SV-EMS-220 connector to provide a large service loop just in case I need to drop the platform the SV-EMS is mounted on for repair/replacement. It looks like a birds nest now, but I'll clean it up with some lacing cord or zip ties. Installed a couple spade connectors on the ends of the right side of the engine (CHT cylinders 1 and 3) along with more service loops. Also added two separate pieces of heat shrink to aid in strain relief. Maybe not needed, but sorta a belt and suspenders approach.

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Mar 12, 2024 More wire routing and TV upgrade - (2 hours)

Category: Avionics

Routed the SV-EMS harness red cube wires to the red cube. Also routed the two wires from the SV-EMS harness to the alternator amp shunt. Got a new TV from the misses as an early birthday gift and mounted it on the shop wall. As you can see from the photo it's a nice upgrade from the old one. Looks great and just in time for March Madness.

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Mar 11, 2024 Stick wiring harness - (2 hours)

Category: Avionics

Installed the stick grip harness for both pilot and copilot sticks. Routed the wires through the left side corrugated tubing with a pull wire. Had to pull left and right wires separately since there is very little room left in the tubing for wires. Was able to route the wires through existing pass throughs in the wing spar and to the vicinity of the bottom of the sticks. Plan to use 15 pin connectors and have the wires exit the stick about half way down (hidden by the stick boot) and into the area below the sticks. Will drill an exit hole in the stick on left or right side since the side loads on the stick will be less than the forward and aft loads. Photo of wires in my hand are the remaining wires from the wing that will have to get to the panel somehow. (Heated pitot controller, nav, taxi and landing light wires)

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Mar 07, 2024 Stick grips, wire routing, Engine sensor harnesses and alt static source - (4 hours)

Category: Avionics

Used some scrap throttle bracket to check the fit of my alt static switch and the protective cover. Seems like it will work well. Now to find some space on the panel to mount it. Received the spacers for the stick grips from Infinity that increase the OD of the stick to fit the ID (1”) of the stick grip. This looks like it will work well after I determine the proper length of the stick, but I need to install the panel to find that, so stick grip progress is on hold til then. Decided to install the engine sensor harness and EGT/CHT (brown wires) harness to the SV-EMS-220. The engine sensor harness connector thumb screws did not want to cooperate, but I was finally able to secure it after getting it exactly square to the opposing connector on the SV-EMS-220. Routed the associated wires from each harness to the appropriate firewall pass through and temporarily taped each wire to the corresponding engine sensor wire (EGT/CHT). Then began process of labeling and routing all the engine sensor wires in the correct portion of the aircraft. LOTS of wires to try and figure out the best and correct placement of each. Trying to not get overwhelmed by the myriad of wires and remember “one wire at a time”. :)

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Mar 02, 2024 Roll servo wires, new dessicant - (1 hour)

Category: Avionics

Installed dsub sockets on roll servo wires and inserted in 9 pin connector. Need to figure out a way to secure the connectors and prevent any interference with the aileron bell crank. Replaced the desiccant on #2 and #4 cylinders and both exhaust pipes.

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Feb 29, 2024 SV-EMS tray, Roll servo wires, Heated seat and Red cube wires - (4 hours)

Category: Avionics

Matched drilled, deburred, and primed the Z bracket to secure the SV-EMS tray. Installed the bracket with AN470 rivets and a nutplate on the tray. The tray is super secure now. Prob wasn't necessary and not the most elegant solution, but makes me feel better about wear and vibration over time. Belt and suspenders. Ran wires from the red cube to the SV-EMS unit, but this prob wasn't necessary since the SV-EMS harness has the wires for the Red cube already. Installed the right seat to try and figure out a good location for the heated seat control. Tried to position the controller between the seat and the side wall, but not sure there's enough room. Decided to install the rest of the right side interior just to see how it looked. Pretty happy with how it turned out. Interior is by Robert Lemke out of Germany. He was great to work with. Decide to pull the roll servo wires out of the right wing and install the sockets and connector on the opposite end so I won't have to try and do this after the wing is installed. Figured it would be easier to install the connector and dsub pins in the panel later. Gonna try and not use a connector at the wing/fuse intersection. Also marked on the stick where the boot reaches. Plan to drill a hole in the stick on the side for the wires to exit. Decided side loads would be less than forward and aft loads on the stick and further away from the bottom weld would be better too.

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Feb 28, 2024 Word from AFS on stick grips - (1 hour) Category: Avionics

Got word from AFS regarding the stick grips and how to utilize the extra two buttons that are not supported by the ACM. AFS sent a new schematic/wiring diagram to show the connections.

Feb 25, 2024 Stick grips and wire ties - (1 hour)

Category: Avionics

Spent some time comparing the AFS wire diagram for the stick grips versus the Infinity grip drawing. I've got two buttons on the grip that may not be functional due to lack of inputs on the stick grip connector. Need to contact AFS for some assistance. Installed some lacing cord on the pitot lines and wires coming into the fuse from the wing. Secured the wires coming forward from the rear of the aircraft thru the wing spar.

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Feb 17, 2024 Tail light wires and stick grip connector - (1 hour)

Category: Avionics

Marked the cabin heat and park brake brackets for holes for nutplates. Spent some time trying to figure out where to drill a hole in the aft bulkheads for the tail light wire. Previous owner drill the holes in the wrong place for the stinger bracket so now I have too many holes too close together for the correct #4 bolt locations. Gonna have to call Vans for recommendations on how to correct this. Thinking I may be able to just add some AN3 bolts in the aft bulkhead without sacrificing edge distance. Also spent time trying to figure out how to make the connection between the stick grip wires and the AFS wiring drawing.

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Feb 15, 2024 More wire security - (2 hours)

Category: Avionics

Added some more lacing cord to the wires in the center tunnel. Also tried to secure the wires in the flap motor tower. Not entirely happy with the extra wire length and loops, so I'll address this again later. Also ordered some more wire to connect the fuel flow transducer.

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Feb 01, 2024 Stick grips - (2 hours)

Category: Avionics

Pulled out the right stick grip and labeled the wires per the instructions. Added an additional tie down for the ELT wires. Removed the electric boost pump to determine a path for the pitot and static lines.

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Jan 31, 2024 Pitot and static line routing - (2 hours)

Category: Avionics

Cut and installed a T for the pitot line to slice it into the fuselage from the wing. It the will supply the ADHRS and the backup EFIS. Routed the static and pitot lines to the panel. Removed the fuel selector to ensure clearance under the electric boost pump. Will prob just route them on the outside of the left corrugated tubing thru the subpanel to the panel since I still need room in the corrugated tubing for wires from the wing lights and pitot heat controller.

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Jan 31, 2024 Pitot tube routing and new wing spar penetration - (3 hours)

Category: Avionics

Added a few tie downs to the flap motor tower to secure the motor wires. Marked the extra throttle plate to cut for possible cabin heat and parking brake brackets. I'll install the panel, sit in the fuselage and try a few possible locations before committing to installing the brackets. Researched the Vans website to determine wing spar penetration locations to add a new pass thru for the pitot and static lines to the backup EFIS. Found a drawing on the Vans website for acceptable hole locations. Measured and measured and measured some more to figure out the best location of the new holes. Marked, drilled, deburred and installed 5/8” snap bushings. Fed the tubes thru and called it a day.

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Jan 29, 2024 Aileron trim wires and servo mount - (4 hours)

Category: Avionics

Finished up the service bulletin on the flap motor rod end. Already had the hole drilled and the wire run just needed to twist it and cut off. Continued to work on the center fuselage tunnel wires. Replaced a few zip ties and installed some lacing cord in between each tie down to further secure the wires. Reinstalled the flap motor wire connectors after removal of the previous ones for rerouting. Temporarily taped the wires in place on the flap motor mount. Need to add a few tie downs to secure the wires. Final installed the aileron trim servo and made the connection to the panel wire using some D sub pins and receptacles supported with heat shrink. Pinned out each wire to the ACM flap/trim connector to verify the wiring before securing the D sub pins. Placed heat shrink around each wire Dsub pin with a larger diameter piece of heat shrink to finish it off. Installation of the aileron trim servo was pretty difficult with the elevator pushrod installed. Required various tools and techniques.

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Jan 26, 2024 Mid fuselage wire runs - (2 hours)

Category: Avionics

Secured SV-EMS cable to tie down I installed the other day to prevent chafing on some rivet ends. Added some lacing cord to several more places in the mid fuselage. Connected the DSub pins for the aileron trim servo. Routed the flap motor wires to the flap motor. Will secure those next session.

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Jan 25, 2024 Defrost fans wire - (1 hour)

Category: Avionics

Installed a D sub pin on the defrost fan wire and inserted into the Aircraft aft ACM connector. Also played around with location of cabin air and park brake cables.

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Jan 24, 2024 Aircraft ACM forward connector - (3 hours)

Category: Avionics

Populated the aircraft ACM forward connector with alternator filed wires. Installed a nutplate to hold an Adel clamp for some wires going to the ACM.

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Jan 23, 2024 Aft wires - (3 hours)

Category: Avionics

Spent a lot of time using lacing cord to replace some zip ties and secure the wiring in the aft fuselage. Added a couple tie downs to prevent chafing on some wires on rivets. Added a lot of lacing cord ties to the aft and center section wire runs.

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Jan 22, 2024 More flap position sensor work - (3 hours)

Category: Avionics

Secured the flap position sensor and mounting bracket with some #6 screws and nuts. Ran the flap motor and spent time adjusting the RC pushrod arm to ensure travel of the flap weldment arm didn't exceed the travel of the position sensor arm. Trimmed the pushrod to length and bent the end at a 90 to fit into the small bracket on the Adel clamp. Secured the sensor wires and connected to the panel wires with D sub pins and sockets. Used some heat shrink for added security and chafing prevention.

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Jan 09, 2024 Tail light and ELT wires - (2 hours)

Category: Avionics

Checked length of tail light and ELT wires. Labeled both ends and installed D sub pins on panel end of wires. Trying to finish up aft airplane wiring for the aircraft rear connector. This connector will be installed in the FlyLeds rear aircraft PWB and into the ACM as shown in the photo.

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Jan 01, 2024 Mounted Hall sensor - (2 hours)

Category: Avionics

Installed nutplates to secure the Hall sensor PWB (for the backup alternator) to the firewall. Used standard rivets to secure the top nutplates and pulled rivets on the bottom two nutplates due to unavailability of space for the rivet gun. Installed the spacers and mounted the Hall sensor PWB to the firewall.

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Dec 31, 2023 Hall Sensor mount - (3 hours)

Category: Avionics

Riveted the seams of the Anti Splat heat shield to fix it in place and installed on the #1 exhaust. Determined the best location for the hall sensor and match drilled for nutplates on the upper firewall. Deburred and drilled center hole for #6 screws. Fabbed spacers out of fuel vent tubing to prevent the back of the hall sensor pwb to contact the firewall.

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Dec 19, 2023 Engine ground wire and voltage regulator wire - (3 hours)

Category: Avionics

Cut to final length the B&C voltage regulator #3 wire and connected it to power on the shunt. Had to change out the smaller snap bushing as it was too large to slide into the 1/2” #6 bushing. Connected the engine ground cable from the engine block to the firewall using a location for a through bolt near the oil filler tube.

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Dec 18, 2023 Connected boost pump gnd wire - (1 hour)

Category: Avionics

Used some extra 14 AWG wire to connect the boost pump to ground. Installed the connectors and ran the wire to the firewall. Not sure where and how exactly I'm gonna make the connection to the aircraft frame.

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Dec 17, 2023 Flap position indicator arm - (2 hours)

Category: Avionics

Fabbed a bracket to connect the flap position sensor and the flap arm. Installed said bracket and connected the RC pushrod to the flap position sensor. Think I'm gonna need a bracket to align the sensor with the arm movement. Also rerouted the wire from the number 3 post on the backup alternator voltage regulator through the firewall with the rest of the power wires.

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Dec 16, 2023 Alternator #2 wiring - (2 hours)

Category: Avionics

Cut the #8 AWG wire to length for the backup alternator and attached a 5/16” eyelet to secure it to the 40A ANL. Added some heat shrink for strain relief. Ran a 18awg wire from the #3 post on the B&C voltage regulator to the post on the ammeter shunt. Will cut to length and attach to the shunt once I receive the 1/4” eyelet for that size wire.

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Dec 15, 2023 ANL limiters - (3 hours)

Category: Avionics

Cut, drilled and deburred the copper bar to connect both ANL 60A and 40A limiters to the ammeter shunt. Added some heat shrink for limited protection. Wire near 40A limiter is from the backup alternator and plan to connect it to the left post. Orientation/angle of the ANL brackets is to enable access to all fasteners through the motor mount.

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Dec 14, 2023 40A ANL and flap position arm - (2 hours)

Category: Avionics

Got some new items from Stein to finish the wiring from the backup alternator to the 40A ANL and mount the ANL block to the firewall. Test fit the ANL block and limiter in position. Marked up the copper bar I received for connecting the two ANLs to power. Found some scrap .063 to use for connecting the flap arm to the flap position indicator with an Adel clamp and RC aircraft pushrod. Marked it up also for cutting.

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Dec 12, 2023 B&C voltage regulator wires - (1.5 hours)

Category: Avionics

Installed another ground wire and power wire to the B&C voltage regulator per the instructions. Not sure if power wire gets spliced into the field wire so I'll try and call them tomorrow. Added another tie down to the AP servo connectors for added security.

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Dec 09, 2023 ANL amp limiter locations - (3 hours)

Category: Avionics

Determined final locations of the two amp limiters for the alternator and backup alternator. The angle of the mounting brackets is for ease of access to the bracket mounting screws and fuse mounting screws around the motor mount. Secured the bracket for the main alternator with the 60 amp fuse and will install the bracket for the backup alternator when it is delivered next week. Used some gasket sealer to seal the holes to the cabin side. Also simulated the backup alternator wire and slipped the Hall effect sensor over it to try nd get some idea of how to mount the tiny circuit board securely. Not sure as of yet how I'm gonna handle that.

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Dec 08, 2023 Pitot heat controller and flap/trim connector - (2 hours)

Category: Avionics

Added heat shrink to flap/trim connector and installed plastic cover. Secured connector to the ACM. Added a pigtail to the pitot heat controller where the previous owner clipped the wires. Got the Hall effect sensor from Advanced Flight for the backup alternator now if I can just figure out where to mount it on the engine.

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Dec 07, 2023 Alternator wire and rear aircraft connector - (3 hours)

Category: Avionics

Cut ACM wire to final length and connected to the cold side of starter relay. Used some extra heat shrink for strain relief. Installed an eyelet on the end of the 8 AWG alternator wire. Will wait for the backup alternator ANL 40A limiter to arrive before mounting the 60A limiter on the firewall and connecting this wire. Removed the wires from the rear aircraft connector to add a large heat shrink for strain relief. Cut the flap trim position sensor wires to final length and installed in the aircraft rear connector. Marked the connector with a sharpie for easy identification of the pin numbers and the name of the connector.

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Dec 06, 2023 ACM power cable - (2 hours)

Category: Avionics

Rerouted the ACM power cable per Vans OP-30 drawing. Decided to use the hole in the firewall that I ran in the first place. Drilled a 1/2” hole in the subpanel to accommodate a #6 snap bushing and ran the power to the ACM through it. Attached an eyelet to the opposite end with some heat shrink strain relief and a rubber boot. Not sure how to attach it to the master relay since I'm out of length on he post. May connect it to the starter relay post. Played around with the 60 amp power limiter location on the firewall.

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Nov 26, 2023 ACM power cord - (2 hours)

Category: Avionics

Cut ACM power cord to length and attached 1/4” eyelet. Master solenoid eyelet bolt is 5/16” so tried to drill out the eyelet with limited success. Gonna prob need to order a replacement with the correct eyelet diameter as important as this connection is.

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Nov 20, 2023 ACM nutplates and ground cables - (1 hour)

Category: Avionics

Cut and installed eyelets on the #10 wire for the ACM ground connection. Drilled and installed nutplates on the subpanel to install AN4 bolts to secure the ACM to the subpanel. ACM only needs AN3 bolts for mounting so drilled out AN4 nutplates. Ugh! Dumb mistake, so will drill subpanel for AN3 nutplates next session. Note to self, put on rubber boots before installing eyelets.

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Nov 20, 2023 Ran the cable for the ACM power - (1 hour)

Category: Avionics

Ran the cable for the ACM power thru the firewall snap bushings

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Nov 19, 2023 ADSB antenna - (.5 hour)

Category: Avionics

Sam helped rivet the backer plate in the rear fuselage for the ADSB antenna.

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Nov 14, 2023 Needed wires - (1 hour) Category: Avionics

Spent some time determining last of the wires I need to complete the wiring.

Nov 05, 2023 Throttle cable - (1 hour)

Category: Avionics

Reinstalled the throttle cable thru the cover plate and with the appropriate sealers/covers that you can see in blue in the photo.

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Nov 03, 2023 Ammeter shunt and throttle cable - (2 hours)

Category: Avionics

Messed with a location for the ammeter shunt and decided the best place would be lower right on the firewall. Removed the throttle cable and drilled the cover plate for a cable pass thru. Made a rudimentary template and used a fuel line to verify Vans location for the hole would work for my cable. Needed to split the called out snap bushings (-6) to make them able to pass over the cable threads. Gonna be a miracle if I can assemble it all back together in the correct order

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Nov 02, 2023 Corrugated Tubing and Andair fuel valve - (2 hours)

Category: Avionics

Removed a nutplate on the F-782 fuel line cover that was chafing the corrugated tubing on the right side. Installed a new nutplate further to the left of the one removed. Secured the corrugated to the firewall stiffener with an Adel clamp. Installed nutplates to the Andair fuel selector valve.

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Nov 02, 2023 Nutplates for ElectroAir EIS controller and corrugated tubing - (2 hours)

Category: Avionics

Removed subpanel rib F-745R to aid in the installation of nutplates. Drilled, deburred and dimpled for nutplates to secure the the ElectroAir EIS controller on the subpanel rib. Worked on placement of the corrugated tubing up the firewall from the sit of the tunnel cover F-782C to prevent chafing.

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Oct 31, 2023 More subpanel nutplates - (1 hour)

Category: Avionics

Drilled, deburred and dimpled subpanel for nutplates to secure the B&C voltage regulator. Installed said nutplates.

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Oct 30, 2023 Nutplates on subpanel - (2 hours)

Category: Avionics

Removed the ElectroAir MAP sensor and the B&C voltage regulator from the subpanel to aid in the installation of the nutplates. Removed the subpanel rib F-745L and installed nutplates for the MAP sensor.

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Oct 29, 2023 Subpanel nutplates - (1 hour)

Category: Avionics

Decided to install some nutplates for the ElectroAir components on the subpanel since it is removed from the fuselage. Drilled the subpanel for nutplates for the MAP sensor.

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Oct 09, 2023 Populated ACM - (1 hour)

Category: Avionics

Populated the ACM with connectors and cables of installed units. Swapped the location of the comm and transponder units to accommodate the cable length. Not much length for adjustments, but may be ok. I'll need to secure these cables and add some lightening hole trim protection if I leave the cable routing as is. Studied the rear connector drawing to try and finalize the wires to that connector.

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Oct 06, 2023 Pitot static tie down - (1 hour)

Category: Avionics

Added a cable tie down to the aft fuse stringer to support the pitot static lines.

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Oct 02, 2023 Coax connectors - (2.5 hours)

Category: Avionics

Trimmed the coax to length for the ADSB, Comm and transponder antennas. Installed two TNC right angle connectors and one BNC right angle connector to attach the coax cables to the main units on the subpanel. Tested all connections for shorts and found one cable that would not test ok. After much consternation, found that when the coax was connected to the antenna it would not test properly. Tested all cables unattached to their respective antenna and all tested ok. Soldering the connections proved to be challenging due to the tiny size and close quarters.

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Oct 01, 2023 Coax cable lebgth - (1 hour)

Category: Avionics

Worked on determining Adsb coax cable length with a service loop. Gonna use a right angle connectors for the connections at the subpanel. These connectors use a solder cup to make the connection to the coax wire, so I'll have to be super careful.

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Sep 21, 2023 ELT Antenna - (2 hours)

Category: Avionics

Match drilled, deburred and primed the ELT antenna tab. Riveted the tab to the aft bulkhead and installed the ELT antenna.

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Sep 17, 2023 AP Pitch servo wires - (2 hours)

Category: Avionics

Bit the bullet and cut the AP pitch servo wires to length. Added a service loop at each end, probably a little too much, but wanted to be safe on the length. Stripped and installed female D sub pins, remembered the the heat shrink and installed the connector with plastic cover.

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Sep 15, 2023 Edge trim and pitch servo wire length - (3 hours)

Category: Avionics

Installed some plastic edge trim to protect against chafing of wires in the aft fuselage (F-707 bulkhead), a lightening hole in the subpanel and one of the lightening holes in the seat rib. Installed the AP servo connector to the pitch servo wires and installed the ACM to determine pitch trim servo wire length. Tried to allow for a service loop without too much excess wire.

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Sep 14, 2023 New transponder coax and labeling. - (3 hours)

Category: Avionics

Replaced the transponder coax cable that turned out to be too short after I rerouted it to the panel through the center of the forward fuselage. Luckily I had some extra coax that was the perfect length. Removed all the coax cables and labeled them. Reinstalled same cables and rerouted the comm cable to the center of fuselage since I had some extra length. Added some heat shrink to the connection end of each cable for strain relief.

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Sep 08, 2023 Rerouting transponder wire, more tie downs and hardware - (2 hours)

Category: Avionics

Rerouted the transponder wire thru the corrugated tubing. May be a little short now. Secured the ELT speaker to the lower F-707 bulkhead. Added several more wire tie downs to the aft fuselage. Swapped out the silver screws on the ELT remote control on the panel with some new 4-40 screws and used a sharpie to blacken the head. Haven't been able to find black 4-40 screws.

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Sep 04, 2023 Antennae doublers and wire lengths - (4 hours)

Category: Avionics

Dimpled and riveted the transponder antenna doubler and installed the antenna. Torqued the nuts and applied torque seal. Was able to reach thru the large hole for the wing plumbing/aileron pushrod and get a bucking bar in place without any help. The ADSB antenna is a different story as the reach is too far for one person. Gonna have to recruit Rosy the riveter for some assistance. Used the Cleaveland close quarters dimple dies and my pull riveter to dimple the holes in the fuselage. Tried to finalize the length of the AP pitch servo wires. Struggled somewhat determining how much of a service loop is needed for these wires.

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Sep 03, 2023 Antennae doubler plates - (2 hours)

Category: Avionics

Match drilled, deburred, dimpled and primed antenna doubler plates for the transponder and ADSB antennae. Had to trim and redrill a couple mounting holes for the transponder antenna due to the proximity of the seat rib.

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Sep 01, 2023 Nutplates on subpanel - (2 hours)

Category: Avionics

Installed nut plates on the right subpanel for the remote ADSB and Comm units. Attached the mounting plate for the remote Comm and mounted the ADSB unit. Primed antennae backer plates.

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Aug 31, 2023 ADAHRS standoffs and wire routing - (7 hours)

Category: Avionics

Decided to try a different method to lower the ADAHRS unit using standoffs from fuel line tubing. Installed two to check for fit and decided this was the way to go. Sorta frustrating that. Spent two afternoons working on the other method, but feel this is better and WAY simpler. Now just need some ss or brass hardware to finish. Routed the SV cable and secured it to the F707 bulkhead. Drilled a hole in a firewall stiffener and installed an Adel clamp for the corrugated tubing. Secured a few more wires, coax,Elt and pitot tubes in aft fuselage. You can see where one of the cable tie downs failed to hold. It was the last of the clik bond glue I was trying to use up, so I'm not surprised. Still gonna need to ensure that the others are secure before flight. Decided to install nutplates on the subpanel for the Comm, Xpndr and ADS units. Drilled, deburred and dimpled subpanel for nut plates. Separated backer plates for two antennae deburred, and prepped for primer.

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Aug 30, 2023 ADAHRS bracket - (4 hours)

Category: Avionics

Fabbed another spacer to the z angles to increase the room at the rear of the ADAHRS bracket for the SV connector. Match drilled the new spacers, deburred and primed the left side. Also added a split fuel line to prevent chafing of the SV cable by the edge of the F-407 bulkhead. Not sure if this will be the final design, but is ok for now.

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Aug 29, 2023 ADAHRS bracket - (4 hours)

Category: Avionics

Removed the ADAHRS bracket and removed the SV-ADAHRS unit. Began fabbing a new bracket that will mount to the underside of the Vans bracket to allow easy access to the unit itself and make any removal/maintenance easier. This will also allow more room for the SV connector at the rear of the ADAHRS. Used some old fuel tank z angles, it they weren't quite thick enough to allow room for the unit. Fabbed some spacers out of some scrap angle I had to help with the height problem of the bracket. Need more room as the pitot connections interfere with the front of the bracket so I'll use some even thicker material tomorrow.

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Aug 28, 2023 SV cable and tie downs - (4 hours)

Category: Avionics

Began the day by drilling several in the mid rear bulkhead (F-704) to enable the installation of zip ties to secure the SV cable to the bulkhead. Adjusted the cable length for service loops and snugged down with zip ties. Installed the aft connector on the SV cable and plugged in to the ADHRS unit. Barely enough clearance to seat the connector, so I may move the ADHRS unit below the bracket where a second ADHRS unit would be. This would allow ease of access to the unit and connector for possible maintenance. Installed several more cable tie downs. Trying to secure all these wires is a PITA especially when instructions are minimal.

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Aug 26, 2023 More ELT wire routing and connections - (4 hours)

Category: Avionics

Installed the female end of the molex connector to the ELT data wire and routed it to the wire from the aircraft front. Installed two wire tie downs on the rear bulkheads for the ELT coax and the data wires using #6 screws. These new tie downs work great on the bulkheads. Rerouted the ADHRS cable and the ELT data wire. Replaced the snap bushing for the ADHRS cable to a larger size.

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Aug 16, 2023 ELT and OAT wiring - (3 hours)

Category: Avionics

Spliced the OAT wires to reach the ADHRS from the left wing and connected them to the ADHRS with plenty of extra if needed. Soldered some 22 AWG wires to the ELT data connector. This was probably some of my worst soldering ever. Super small solder pins and in close proximity. Secured the connection with some heat shrink and slathered in some RTV for strain relief. Forgot to put the connector cover on prior to make the solder joints. Had to cut the wire and install a molex connector. Always something.

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Aug 14, 2023 Flap motor connectors - (2 hours)

Category: Avionics

Researched the installation of Faston connectors (ES 421-0107&-0108) and installed them on the flap motor wires. Used my new crimper for the first time. Have plenty of extra wire for a service loop, so need to figure out how to secure that.

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Aug 12, 2023 Trim wires - (2 hours)

Category: Avionics

Installed sockets on the roll trim wires and installed pins and sockets on the flap position sensor wires. Also installed pins on the pitch trim servo wires. Had to rerun the flap position wire due to a co flirt with one of the control cables. Hopefully done running and rerunning aft aircraft wires.

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Aug 11, 2023 Reran wires - (4 hours)

Category: Avionics

Spent the afternoon rerunning wires through the corrugated tubing on the firewall and attached pins to the roll trim servo. Plan to use the Stein technique of pins and sockets fastened with shrink tubing to make the connection. The other option is to use D-sub connectors. Finally able to start cleaning up some wires, especially to the rear of the airplane.

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Aug 07, 2023 Wire tie downs - (3 hours)

Category: Avionics

Cut a splice for the OAT wires. Used some extra black wire on hand since the polarity of the wires didn't matter and twisted the pair using my drill. Ran the wires thru the corrugated black tubing and ran it up to the ADHRS via the pitot lines. I'll connect the OAT at the wing root later. Installed the zip ties in the tie downs and loosely tightened the zip ties around the appropriate wires. Tried to figure out the rest of the wire routing on the firewall. Think I'm gonna install some more corrugated tubing and secure that per Vans drawing up the side of the firewall stiffeners.

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Aug 04, 2023 Connectors and tie downs - (4 hours)

Category: Avionics

Spent some time trying to figure out what I needed to connect the elevator and aileron trim wires to their respective harness. Found a Stein video that shows an easy way to make the connection with Dsub pins. Ordered some pins and coax connectors to try and finish off the some of the wiring to those components. Mixed up some Clik-bond and secured 11 tie downs for the wires going aft through the center channel. Had to work quickly as that stuff sets up fast.

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Aug 01, 2023 Pitot lines and flap sensor wires - (2 hours)

Category: Avionics

Cut the pitot line and ran it to the rear of the airplane through the corrugated tubing. Cut a slot in the corrugated tubing and ran the flap position sensor wire through it. Opened up a tooling hole for a snap bushing and routed the wire through it. Cut the static line and connected it to the ADHRS. Installed a snap bushing in the upper rib to route the static line to the ADHRS. Also connected the pitot and AOA lines to the ADHRS. Used removable zip ties that have rubber on the inside for now. Tried to secure the pitot lines, but need a couple more attach points. Installed the exhaust desiccant plugs I got from ACS last week that have been on back order forever. Spent 7/23-7/27 at OSH. Had a great time with Sam.

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Jul 20, 2023 Finished tubing runs - (2 hours)

Category: Avionics

Installed the two remaining brackets and ran the corrugated tubing to the aft fuselage. Cut a piece of the AOA tubing from the wing and ran it aft. Also ran the static line forward for the standby EFIS. On a side note, I dropped the manual pull riveter on the floor of the fuselage and left a nice dent. Hoping the paint shop can work that out.

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Jul 19, 2023 More corrugated tubing brackets - (4 hours)

Category: Avionics

Fabbed another set of brackets for the second tubing run. Deburred, scuffed and primed each bracket. Installed the two aft brackets. Decided the ones for the front were not the correct dimension from the floor rib so fabbed a couple more. Seems like it always takes a few tries before getting it right.

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Jul 18, 2023 Corrugated tubing runs - (3 hours)

Category: Avionics

Fabbed a couple new brackets for under the baggage floor for a little more length. Deburred, scuffed and primed brackets. Installed the brackets with pulled rivets due to lack of space and installed the corrugated tubing. Man that stuff is a PITA to pull thru the holes.

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Jul 17, 2023 Tubing angles - (1 hour)

Category: Avionics

Match drilled two of the angles Sam made to the baggage floor rib.

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Jul 16, 2023 Flap/trim connector and corrugated tubing brackets - (2 hours)

Category: Avionics

I installed the vinyl tape and plastic connector cover on the flap/trim wires. While Sam began fabricating brackets for the corrugated tubing to be installed in the floor of the baggage compartment and seat panels. I also began working on the pitot and AOA bracket to secure the connectors for the tubing and aluminum tubing from the pitot tube.

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Jul 15, 2023 Flap position wires - (1 hour)

Category: Avionics

Stripped the ends and installed pins on the flap position wires. Installed pins in the flap/trim connector.

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Jul 11, 2023 Corrugated tube mount - (1 hour)

Category: Avionics

Fabbed up a prototype bracket to hold the corrugated tube runs to the rear of the aircraft. Gonna need 8 of these for the two runs. Think it'll be a good project for Sam when he's home this weekend. One run will be to get the statictube forward and the pitot and AOA tubing aft. The other run will be for possible future wire needs. As you can see in the photo, a lot of nutplates were removed. Previous owner used the wrong type nutplates to secure the bottoms of the baggage panel. (K1100s) Plan to use leftover baffle scrap to make the brackets and pop rivet them to the seat and baggage floor ribs.

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Jul 10, 2023 Removing Floor panels - (3 hours)

Category: Avionics

Spoke with Vans tech support about getting the pitot and AOA tubing back to the ADHRS unit mounted in the upper portion of the rear fuselage. Decided the best route to go was to remove on set of floor panels to provide access to some tubing to run the pitot lines and possible future needed wires. Since the pitot lines come in from the left wing that's the side I removed. Removal went fairly smoothly with the exception of the rear nut plates. It was difficult to get the drill perpendicular to the rivets to prevent elongated holes. Nothing completely unacceptable, since the holes are just to keep the nutplate from rotating. All in all not as bad as I thought it was going to be.

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Jul 04, 2023 Finding room and a route - (2 hours)

Category: Avionics

Worked on trying to find space for all the cables going to the rear of the airplane. Decided the corrugated duct would not fit thru the holes made for the 5/8” snap bushings. I can get all the cables I need aft with the exception of the 1/4” SV cable that goes to the ADHRS. It fits in a 1/4” snap bushing perfectly, so I just need to find a route that will work to get past the bulkhead just past the baggage area.

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Jun 30, 2023 Pitot - (1 hour)

Category: Avionics

Tried to do some planning on how to attach the pitot lines to the pitot tube using some sort of bracket.

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Jun 29, 2023 Antenna coax connectors - (4 hours)

Category: Avionics

Practiced stripping coax for the xpndr, comm and adsb antennas. Watched Steins video and used my new jonrad tool. Took a few tries as you can see haha, but I finally found a technique that produced acceptable results. Installed male connectors on the end of each cable run and crimped in place. Crimper worked well for both the pin and connector. Used the voltmeter to check for shorts. Discovered the opposite ends required the screw on version so I'll need to order those. Always something. Spent some time trying to determine the best place for the GPS antennas. Not crazy about putting them under the cowl due to heat and vibration, but don't want to put them on the upper rear fuselage either. May try and get some ideas at OSH for those.

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Jun 23, 2023 Coax and ADSB antenna - (3 hours)

Category: Avionics

Figured out I can get more wires through vans corrugated tube than a snap bushing. Found I could get the SV cable and coax and elevator servo wires through the aft pass through hole near the baggage wall. Ran the antenna coax wires for the transponder, comm and Adsb antennas. Played around with a new coax wire stripping tool with limited success. Worked on a permanent location for the Adsb antenna.

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Jun 22, 2023 Transponder and comm antennas - (3 hours)

Category: Avionics

Took the plunge and installed the transponder and comm antennas. Decided to mount them under the pilot's and copilot's seat pan. Makes for a short run to the panel. Also ran the SV cable to the ADHRS in the rear of the airplane . Not exactly sure how to route the cable, Checked to see if I can get the SV cable and two coax cables thru one snap bushing. May have to install Vans corrugated tubing after all since it has a larger inner diameter.

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Jun 19, 2023 Pitot tube and bracket - (2 hours)

Category: Avionics

Countersunk to holes for additional rivets in the pitot mast and dimpled the holes in the skin for 426-3 rivets using the blind rivet puller and dimple dies from Cleaveland tool. Also trimmed the angle to fit under the lightening hole in the wing rib and for an adjacent rivet. This should finish up the pitot mast until it's time to final install.

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Jun 18, 2023 Pitot tube and support bracket - (2 hours)

Category: Avionics

Transferred the hike markings on the pitot mast to the lower right wing skin and match drilled the six additional holes for support. Fabbed an angle that Dynon suggests to provide additional support to the pitot tube. Dynon calls out to use a 1”x1” angle, but the hole in the mast I'm going to use for support is 1 1/4” away from the nearest rib so a custom support is needed.

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Jun 16, 2023 Marked pitot mast and coax cable routing - (1 hour)

Category: Avionics

Marked the pitot mast for additional supporting rivets and transferred to the lower right wing skin. Tried to figure out coax cable runs to antennas. There's limited space left for any more wires going through the aft pass through snap ring bushing.

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Jun 09, 2023 Pin removal tool and flap/trim connector - (1 hour)

Category: Avionics

Removed pins installed in error in flap/trim connector using the new removal tool I received. Tool worked well and reinstalled roll and pitch trim pins into flap/trim connector. Also did some rerouting of wires to get wire to connector aligned through the forward snap bushings. Pictures also include broken, cheap plastic removal tool.

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Jun 08, 2023 Antenna wire planning and pitot mast bracket - (2 hours)

Category: Avionics

Spent some time trying to determine the best locations for the 3 antenna I need to install and the routing of the associated cables. Fabbed a1x1 angle to help support the pitot per the Dynon instructions. 1” is too short to reach the pitot mast so I'll try and use some 1.25x1 angle I have on hand and see if that will provide sufficient edge distance. Also discovered the mast interferes with the adjacent rib flange. Will need to trim about 1/32” off of the inboard edge. Felt the interference with my finger and verified it with the borescope as you can see in the photos.

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Jun 07, 2023 More tie downs and labels - (5 hours)

Category: Avionics

Cleaned off the area in the center of the fuselage and forward of the wing spar to attach tie downs for forward wires. Masked off the center of the tie downs to prevent blocking of the channel that the zip ties pass through. Did not do this in rear fuselage and installing the zip ties there was difficult to say the least. Labeled pitch and roll trim wires and attempted to install them in the flap/trim connector. Had the connector upside down and inserted the pins in the wrong location. Broke the plastic removal, so new beefier one is one the way from Amazon. Installed OAT probe in the bottom of the right wing where Vans had a hole in the quick build wing for a pitot probe. Worked well and had just enough room left in the snap bushings to run the wires. Place some fuel line around the wires where they exit the OAT to prevent chafing with the pitot line.

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Jun 06, 2023 Pitch and roll trim pins, ELT wire - (5 hours)

Category: Avionics

Stripped and installed pins on pitch and roll trim 5 wires at fwd ends. Set up label maker and labeled bundles. Will label each individual wire too. Also installed pins on flap motor wires. Ran wire (phone type) to ELT. had to remove and remove and reinstall tail light and pitch trim wire bundles to allow the ELT wire room to pass through the snap bushings. Need to order larger diameter heat shrink tubing for wire bundles for printer. Need to figure out a good mounting location for the ELT speaker.

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Jun 05, 2023 Wire tie downs in aft fuselage - (5 hours)

Category: Avionics

Cleaned up locations for the farthest aft 3M wire tie downs. Mixed up some Clik Bond and secured tie downs to aft fuselage floor. Opened up tooling hole in aft fuselage bulkhead to accommodate the tail light wires and elevator trim wires. Installed a 5/8” snap bushing in said hole. Fabbed a bracket to attach to he aft bulkhead to secure the ELT antenna under the empennage fairing. By turning the antenna mount will provide adequate clearance over the HS spar. Will secure the wire part of antenna later. Used some old house wire to get a good length for the throttle cable. Looks like I need between 52-53”. Will call Vans later for new cable unless I can adjust the one I have to make it work.

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May 23, 2023 Roll servo safety wire - (1 hour)

Category: Avionics

What a difference a day makes. Safety wired the two lower bolts on the roll servo mount and was successful on the first try. Drilled a hole in the upper bracket using the pneumatic drill and safety wired the upper bolt as well. Went surprisingly well given the tight quarters of the access hole. Safety wire remains from previous tries.

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May 19, 2023 Roll servo range of motion limiting bracket - (2.5 hours)

Category: Avionics

Connected aileron pushrod to check aileron limit of travel to check full travel with limiting bracket. Had to trim range of motion limiting bracket to clear mounting bolt and rotate the limiting bracket slightly clockwise. This bracket prevents the servo arm from going over center and locking. Tried to safety wire the bottom bolts of the servo bracket, twice without much success, at least to my satisfaction. Will try a third time next session. Hard to get adequate access through the inspection hole. Not sure how I'm gonna be able to safety wire the 3rd bolt on the back of the servo bracket. Will check some other builder sites to see how they did it.

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May 16, 2023 Roll servo over center bracket - (1 hour)

Category: Avionics

Removed the auto pilot roll servo and began to install the roll servo over center bracket. Need to connect the aileron to ensure full travel. Ran out of time.

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May 13, 2023 Roll servo wires and throttle cable pass through - (1 hour)

Category: Avionics

Sealed the hole in the firewall at the throttle cable pass through with snap bushings and permatex gasket maker. Guess it is in the category of “the bigger the blob the better the job”. Ran the wires in the wing for the A/P roll servo. May have to disconnect the connector to run the wires in the fuse.

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May 04, 2023 Finished SV-EMS mounting tray - (1 hour)

Category: Avionics

Installed and torqued all fasteners for the SV-EMS 220, mount plate, ElectroAir MAP sensor and the BC backup alternator voltage regulator. Hopefully not asking the subpanel rib to support too much weight.

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May 03, 2023 SV-EMS 220 tray - (3 hours)

Category: Avionics

Removed left side of sub panel, F-745L, to match drill for the support angle. Located and match drilled angle to subpanel and mounting tray. Installed 3 nut plates to subpanel and match drilled all to mounting tray. Drilled and trimmed mounting tray plate for the SV-EMS 220 unit. Primed plate.

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Apr 29, 2023 SV-EMS bracket arm - (1 hour)

Category: Avionics

Primed the angle and riveted the reinforcements to the SV-EMS bracket arm.

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Apr 28, 2023 SV-EMS bracket - (1 hour)

Category: Avionics

Made some reinforcements for the SV-EMS bracket to support and strengthen the angle that will support the tray.

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Apr 27, 2023 Wiring and avionics mount - (3 hours)

Category: Avionics

Installed some zip ties loosely, in case I need to add more wires in the ties downs I glued down the other day. Began fabbing a mount on the subpanel for one of the avionics boxes that connects to the engine sensors and various other wires. Dynon calls it the SV-EMS-220. Only took me 3 tries to fab a support that didn't crack when I bent it. Amazing what a small relief hole can do.

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Apr 21, 2023 Aft wire tie downs - (1 hour)

Category: Avionics

Mixed up some clickbond and set some wire tie downs in the aft fuse.

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Apr 20, 2023 Wire securing - (1 hour)

Category: Avionics

Placed the wire tie downs in some MEK to remove the foam backing in order to glue them in the fuselage. Also measured and marked several locations in the aft fuselage for placement to use for the rear fuse wires.

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Feb 28, 2023 Throttle brackets

Category: Avionics

Received new throttle brackets from AFS. Going to try out both to see which one I prefer.

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Feb 24, 2023 Roll servo connector and tie down - (1 hour)

Category: Avionics

Installed the roll servo connector and tapped the hole near the access panel for the tie down to 3/16.

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Feb 23, 2023 Pitch servo wiring - (3 hours)

Category: Avionics

Thanks to YouTube I was able to figure out how to use the DMC crimper tool I got earlier this year. Used it to wire up the dsub connector to the AP pitch servo. Installed the pitch servo in the aft fuse on the bracket I installed a while ago and safety wired the attachment bolts. Had to drill a small hole in the bracket to secure one of the AN3 bolts. Used the extractor tool and removed the pins from the AP roll servo connector. Added pins to a couple wires per the wiring diagram and will install a new connector received from my avionics supplier . (AFS)

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Feb 22, 2023 Pitch servo wiring - (1 hour)

Category: Avionics

Spent some time trying to understand the wiring diagram for the pitch servo. Going to attach one d sub connector to the servo and then install the servo. Pulled out the DMC crimper and need to figure out how to use it.

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Feb 21, 2023 ELT antenna - (1 hour) Category: Avionics

Think I found a way to mount the ELT antenna under the empennage fairing. Just need to make a bracket.

Feb 16, 2023 Flap motor wire - (.5 hour)

Category: Avionics

Routed the black/ ground wire to the flap motor.

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Feb 15, 2023 Flap motor wires - (.5 hour)

Category: Avionics

Measured, cut and routed the wires to the flap motor.

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Jan 09, 2023 Finished elevator trim pigtail - (1 hour)

Category: Avionics

Completed soldering of elevator trim servo pigtail. These 26 AWG wires are delicate and hard to work with. Installed heat shrink on each wire and a larger one around them all.

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Jan 06, 2023 Elevator trim servo wires - (1 hour)

Category: Avionics

Added a pigtail to the elevator trim servo wires to extend them into the fuse, where I plan to add a connector. Used my new Santa gift to strip and solder the 26 AWG wires. Glad I had the new magnifying specs as these wires are TINY.

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Dec 21, 2022 Elt shielded wire - (1 hour)

Category: Avionics

Ran some 22 AWG wire to the ELT for GPS information.

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Dec 01, 2022 ELT and wing wiring - (3 hours)

Category: Avionics

Studied and planned the ELT wiring. Determined location on the subpanel for the ELT mini speaker. Need to get some 4-40 screws to mount. Pulled the old wires out of the left wing with the exception of one. Used the last old wire to pull the new position, strobe and taxi light wires in the left wing.

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Nov 29, 2022 Elevator trim wires - (1 hour)

Category: Avionics

Installed several plastic snap in bushings in the aft bulkheads that were predrilled for wires. Ran a five strand 20 AWG wire to the tail for the elevator trim. Plan to install some wire tie downs on the floor of the fuse to secure the wires for the taillight, elevator servo and ELT.

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Nov 20, 2022 Avidyne Nav rear support - (3 hours)

Category: Avionics

Finished installation of angle to support the rear of the Avidyne Nav tray. Match drilled, deburred and primed angle prior to riveting to the subpanel. The angle attaches to the tray with #6 screws. Made some spacers to ensure an even gap around tray and subpanel. Also spent some time inventorying the cables and connectors from Advanced Flight to determine what wires I need to complete the avionics installation.

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Nov 19, 2022 More planning and avidyne tray mount - (4 hours)

Category: Avionics

Spent time trying to determine best way to mount the SV-220 box. May just use some rails between the subpanel ribs. Also fabbed an angle to support the aft of the Avidyne nav tray. Need to determine if I want to rivet it to either the tray or the subpanel. Lot of time in the shop with not much done. Watching too much foootball while trying to work. Haha

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Nov 19, 2022 More component placement - (1.5 hours)

Category: Avionics

Spent some more time trying to determine the location for the SV-EMS-220 box. This is the controller for the engine monitors (EGT and CHT). Connected the cables to the box for a better idea of the footprint needed to find a location. Connected the FlyLeds controller board I picked up at OSH that works with the ACM to the Advanced ACM and tried to figure out the wiring and connector needed.

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Nov 17, 2022 Filling the subpanel - (3 hours)

Category: Avionics

Located the final position of the ADSB transceiver, remote comm and transponder, backup battery and Advanced ACM. Marked, match drilled and deburred the subpanel for all said components.

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Nov 12, 2022 Panel attach angles - (6 hours)

Category: Avionics

Riveted vent angles to side of fuselage. Riveted small angles to side and top of fuse gusset. Could reach the outboard rivets with the squeezer, but not sure how I'll reach the inboard rivets as they are under the bent in portion of the gusset.

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Nov 11, 2022 Panel brackets and vents - (6 hours)

Category: Avionics

Secured the instrument panel in place and marked attachment brackets for rivets in fuse. Match drilled the brackets, deburred and riveted lower brackets in place. Match drilled and deburred the upper brackets, but did not rivet in place. Will rivet later. Fabbed two F-793 angles for the left and right vents from Advanced Flight. Match drilled to fuselage and vent bracket. Scuffed angles and primed.

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Nov 10, 2022 Subpanel cutout for Avidyne GPS - (4 hours)

Category: Avionics

Measured, remeasured and marked the lower center subpanel for a cutout. The Avidyne GPS tray extends forward past the center subpanel, a cutout had to be made to allow room for the tray to pass through the subpanel. Spent a lot of time ensuring I got the location correct. Gave myself about 1/8” gap around the tray and will attach the tray to the subpanel with an angle later.
Removed the comm and autopilot panels to make the process easier, but not before taking a couple photos to make sure they get reinstalled correctly.

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Nov 08, 2022 More subpanel work - (3 hours)

Category: Avionics

Match drilled, deburred and dimpled the left subpanel rib. Riveted the angle to the subpanel ribs and attached both ribs to the instrument panel to locate the ribs on the subpanel. Glad I did this as my previous location was incorrect. Got the ribs in the proper location to ensure room for the avidyne navigator and marked the subpanel in order to match drill for rivets. Removed the instrument panel and subpanel from the fuse and match drilled the ribs to the subpanel. Should be able to mark and install components to the subpanel now that I know where the ribs will be.
On a side note, I missed one hole when dimpling the rib angle and ended up with two holes. Instead of replacing the rib I just added a rivet hole and rivet on each side, plus a rivet in the correct hole. Don't think this is a big deal, since I'm moving the ribs anyway. First time I've done that. Sorta like drilling through your finger; there are those that have and those that will. Haha

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Nov 07, 2022 Subpanel ribs - (1 hour)

Category: Avionics

Clamped the subpanel ribs I cut off to the actual ribs in order to get the placement correct on the center panel. These ribs had to be cut off and placed more inboard in order to make room for the EFIS screens. Marked the upper and lower locations of the cutoff ribs and match drilled and dimpled the new angle to the right rib.

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Nov 03, 2022 Subpanel ribs - (2 hours)

Category: Avionics

Spent some time trying to find the new location for the subpanel ribs. Decided to remove the EFIS screens to make the process a little easier. Needed five hands to keep the panel in place, so I clamped some wood blocks to the fuse to keep the panel from sliding off the fuse rails. Was able to get pretty close approximation of where the ribs needed to be.

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Oct 31, 2022 Panel Attach angles - (1 hour)

Category: Avionics

Screwed attach angles to the panel in order to secure panel to the fuselage. This will also enable me to locate the holes for the modified subpanel ribs that had to be removed to avoid interference with the EFIS displays. Had to rivet a nutplate to one angle that I neglected to install before. Made some initial layout markings for the remote comm, transponder and backup battery locations.

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Oct 27, 2022 Trimmed subpanel and avionics layout - (2 hours)

Category: Avionics

Trimmed F-786Bs, subpanel outside pieces, for interference with the fuel vent lines. Tried to layout some components on the subpanel for mounting. Avidyne GPS navigator interferes with the middle section of the subpanel. Not sure how to address that at this time. May have to cut out a portion of the lower section to allow room for the GPS tray. But it will still interfere with the canopy release mechanism. Think I'll use a suggestion from AFS regarding placement of the remote comm and transponder along with the ADSB transceiver. ACM will be mounted on the left section of the subpanel.

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Oct 25, 2022 Panel delivered - (1 hour)

Category: Avionics

Panel from Advanced Flight Systems arrived today. Unpacked the panel, but left the rest of the boxes in tact until I get some time to sort them out. The large hole above the switches is where the Avidyne nav unit will go and the square blank is for the backup EFIS that I will get later.

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Jul 14, 2022 ELT and B&C voltage regulator - (3 hours)

Category: Avionics

Match drilled ACK ELT mount to aft fuselage support (F-729A), bellcrank support and installed. Decided this location was way better than using the Van's ELT bracket that was designed for an older ELT with difficult to reach rivets and possible rudder cable chafing. Match drilled B&C voltage regulator to subpanel rib. Instructions say you can mount it on the firewall, but sticker on the regulator itself says to mount in cabin away from heat and vibration close to the panel. So subpanel it is.

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Jul 11, 2022 Elt mount - (2 hours)

Category: Avionics

Spent time trying to figure out how to install the Van's Elt mount. Bind/pull rivets are gonna be difficult to reach and looks like chafing with the rudder cable is a definite possibility. Researched VAF for ideas. Also need to drill new holes for mount as the ones predrilled will not work.

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Jul 01, 2022 ADHRS - (.5 hour)

Category: Avionics

Spent a lot of time reading installation instructions for the Advanced Flight boxes I received. Got some good input from the folks on VAF and installed the ADHRS on the bracket I had previously installed at one of the rear bulkheads. Got a draft from Evoke/plane schemers that I feel is pretty close to final. Spent a short amount of time sanding down the spots where I filled the forward holes on the cowling for the hinge pins.

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Jun 27, 2022 Avionics - (.5 hour)

Category: Avionics

Received a big box of avionics to include the ELT and antennas.

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Jun 06, 2022 Heated seat switches - (1 hour)

Category: Avionics

Spent some time trying to decide if the heated seat switches would fit on the lower throttle bracket I plan to install

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Mar 13, 2022 Stick grip and canopy fairing - (2 hours)

Category: Avionics

Removed push button in #3 position on left stick grip. Installed and soldered toggle switch in same position for flap control after hearing from JD I did the right grip correctly. Sanded the never ending canopy fairing and reprimed.

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Mar 12, 2022 Infinty stick grip - (2 hours)

Category: Avionics

With the Advanced avionics I'm using the flap position indicator will not work. Need to order a different type and also needed to change a push button on the Infinity stick grips to a toggle. Ordered the toggle switches and began changing them out. Opened up the stick grip to find a mass of wires and several buttons to choose from for removal. I decided to go with the manufacturer recommendation to put the flap toggle switch in the #3 position. (Upper left on right grip and vice versa on the left grip). Removed the button and clipped the wires. Stripped and resoldered the wires to the toggle. Soldered the connections per the wiring diagram in the instructions, but not sure of correct orientation. Will wait to do the other grip until I hear from the manufacturer.

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