Jul 17, 2021     Avionics - continued - (45 hours)       Category: Avionics

I took about 1.5 weeks off from the build so I could run a race and visit family in KCMO. It was a nice break but missed building! Since my last post in June I've completed the following:

- Configured G3X system along with all other devices
- Mounted panel permanently
- Fitted glare shield
- located and ran all wiring to antenna's (except ones that will be mounted on wing)
- Wired all headset and mics (crossover console)
- Ran wiring for battery charge system w/n cockpit
- Connected autopilot cables to capstans (need to wait to tighten cables prior to final adjustments)
- wired XFER pump discrete to G3x
- Finished connecting static and pitot lines to avionics
- ordered throttle, prop, and throttle cables from McFarland
- mounted ELT system
- mount fresh air vents (sure wish I had mounted these PRIOR to install the firewall!

  Aug 16, 2021     Label Panel - (2 hours)       Category: Avionics

Not sure if I'll keep these labels permanently but for now they will do. They came out pretty good and are functional...and look better than my green tape!

  Aug 07, 2021     Install Cabin light - (3 hours)       Category: Avionics

Installed LED Red/White cabin light in crossover cable cover and made it dimmable via the G3x system using the GAD27 PWM option. Pretty cool! I don't think I'm going to need dash lights as everything is lit pretty well.

I purchased the 754 Series LED Light from ACS: https://www.aircraftspruce.com/catalog/pspages/754cockpitlights.php?clickkey=7189
The SPDT three-position switch came from Amazon: https://www.amazon.com/dp/B07LBMTWB6?psc=1&ref=ppx_yo2_dt_b_product_details

  Jun 24, 2021     Avionics Wiring - (50 hours)       Category: Avionics

Yeah....I'm nearly done with all the wiring for the Avionics...whew..did I ever underestimate "building your own panel". I've sort of lost track of the hours I have in this part but it's a lot. This past two weeks I've spent at least 50+ hours on the panel. I learned so much through this process and while it was frustrating at times, it was also fun to overcome the challenges. When the panel powers up and everything is working there is a high amount of satisfaction. I know I still have lots to figure out and configure but at least most of the devices are connected and reading correctly in the G3x.

  Jun 06, 2021     Avionics Wiring - (30 hours)       Category: Avionics

Great week of solid work wiring the panel. I was able to get in the flow and make great progress and I'm happy to report that ALL LRU's have been wired with their CANBUS, RS232 wires in addition to various other connections. This weekend I spent much of it troubleshooting a few devices that were not communicating correctly (GSA28, GEA24). I had three wires that needed to be switched and one bad crimp on a PWR wire to the GSA28. Otherwise, after I worked through the configuration process via the G3x manual, everything is communicating now with the exception of the GAD27 and the NAV 1 on the GNC255. I've spent hours trying to figure them out but finally stopped and sent an email to G3xpert for assistance. I have plenty to move forward on such as the lighting bus and wiring the GMA245 heard set / PTT switches in the control sticks. Excellent week of progress and I'm looking forward to another productive week.

  May 30, 2021     Avionics Wiring - (30 hours)       Category: Avionics

I continue to make progress on the wiring and FINALLY have a good mental model in my brain on how this system works. It took me a few times to get it straight in my head but now I can see the systems and how they all interconnect. I have all the PWR circuits done to the main avionics and everything tested out perfect and no smoke was seen or smelled during the first power up.

Now that school is over for the summer I can dedicate nearly unlimited time to the wiring and I've found it much easier to get in the flow of wiring w/o stopping. I have my CAN BUS system designed and love the simplicity of the system. I've read and figured out all the “non-G3x” equipment manuals such as GNX375; GNC255; and GMA245.

As of today (Sunday May 30th) I have the GMU11; GSA28 (roll) GSA 28 (pitch); GAD29 all completely wired. I have the CAN bus and PWR to the GTR20 but need to return to this device later when I wire-up the GMA245.

Only 7 more devices to wire into the CAN Bus system!

  May 09, 2021     Avionics Wiring - (5 hours) Category: Avionics

Finished wiring the Alternator circuit, alt switch, Master switch, and then started in on the Avionics master switch. Waiting on diodes that are on order. Since Radio Shack closed down years ago you just can't find any small resistors and diodes locally any more!

  May 08, 2021     Panel Build and Wiring - (25 hours)       Category: Avionics

OMG....I cannot believe that it has been 3 weeks since my last update. I've been making forward progress with lots of design issues almost overcome and ordering small parts here and there. I have most of the wiring, connectors, relays, circuit breakers, grounding buss, and other minor items either on the way or already here. I kept going back and forth on the Avionics master relay and finally decided to keep the switch and associated relay. Reading AeroConnection is very helpful but there are some ideas put forth that were conflicting with what I was seeing in other builds. I think I've mentioned this before but the quick evolution of newer technology has outpaced some of the suggests made in older avionics examples. Another example is the TWC battery back-up system, which included all the diodes and circuitry that protects devices from being backfeed when in use. The Garmin avionics also have connections for primary power and back-up power so they know when you are on ‘main' vs. ‘back up' power.

You can see below the modifications made to my circuit breaker and I worked through the ‘E-Bus', Avionics bus, and main bus. I think I now have it all figured out!

I have all the CHT/EGT wires run through the FW along with ALT and Starter wires. I missed ordering butt splices and male spade connectors to connect to the fuel pressure, oil pressure, and oil temp sensors and I don't want to use ‘automotive' grade so i'm waiting for those to come in from ACS. I'll continue with finalizing the grounding strip and various other items when finish up all the FWF wiring this next week.

I'm getting a feel of the Garmin G3X manual and once I have the FWF devices through the FW I am optimistic that progress will speed up!

Prop should ship this next week and I'm working on my FAA 8050-3 Registration paperwork for N45HS (reserved number took 12 weeks for approval!).

  Apr 17, 2021     Panel Build - (15 hours)       Category: Avionics

Lots of work on the panel build over the past few weeks and I'm very happy with the final product. I was going back and forth on the Aera 760 but went ahead and cut the hold and installed the AirGizmo panel mount. Its not as clean of an install as the other components but all the other homemade options I considered would have been worse. The faux carbon overlay turned out very nice. I put some on a test piece a while back and its been doing really well with 409 cleaning and general handling. It will still tear if sharp edges come in contact but that's to be expected.

98% of holes are cut in the panel. The only remaining items (I think) are the EFIS battery switch,....which I ordered this weekend.

The buss bar material all came in today so I can start building the buss bar systems and begin to wire!

  Apr 06, 2021     Remote mount devices - (3 hours)       Category: Avionics

Finished up mounting the TWC battery back-up, GAD 27, and installed all connectors to look for any interference issues. Also mounted master and starter contactor and shunt. Had to move GAD 29 back a little as the clearance was too small with the connectors installed.

  Apr 03, 2021     Avionics Design and Install - (15 hours)       Category: Avionics

Lots of computer work this week with the design of the rest of the avionics. I made the final decision to NOT use ECB's and stick with the normal pull breakers. I had reviewed the ECB option (Vertical power) a while back but wanted to review it again to make sure I did not want to go that direction. Its tempting because it simplifies the install and wiring but I don't like how I am tied to a a system that is dependent on working with Avionics manufacturers to program the breakers. If VP should go out of business I would be stuck with a system that is not supported. Using pull breakers makes the install a little more complicated but the technology is proven.

I ordered all of the breakers, switches, and wire (most of it) this week from three different suppliers (ACS, DigiKey, and B&C). I double checked all of my amp draws and panel design prior to orders...which took a lot of time.

I'm also reading AeroConnections and Aircraft wiring books to help fill in the gaps. I'm trying to use the KISS approach and don't want to spent a ton of time building schematics within Autocad. I'm using ones that already exist as red-lining them. The circuits are pretty simple and the G3X manual has all the pinout data that i'll use when I start the actual wiring.

I also received the AutoPilot install kit from Glasair this week so I installed this kit sans the actual connection to the cables...which I'll wait until I mount the elevator and wings. This was a nice kit and saved me some design time and ordering parts from various suppliers.

I have all of the remote devices now and will finish up installing them this weekend, I plan to have the panel design and hopefully most devices mounted in the panel by the end of next week. Then...I can start wiring!

  Mar 25, 2021     Avionics design and install - (25 hours)       Category: Avionics

Another productive few weeks but more of the time was spent on design work vs. building. I created DXF files from CAD drawing obtained from another Sportsman Builder (Thanks Dan Lodge). My layout is going to be different so the outline of the center panel was correct and the G3X but I had to measure and redesign the other cutouts. I sent them to a company called ‘SendCutSend' and they turned them around very quickly. I made the inserts out of 6061 .063” and I'm really happy with the center one. The Left panel insert had holes here I thought I had deleted them but they must have been imbedded into another layer that I missed. I used the left panel as a patter then made my own. I also made my own Right insert panel. The 6061 is much more brittle than the other aluminum I've been working with so grinding took more effort.

Today I finished all the cut out for the panel and cut all the openings for the avionics. That Carbon is difficult to cut and makes a mess. I tried using my oscillating cutter but it was chipping the paint and leaving a jagged edge. Used the dremel cutting disc and it worked well but makes a mess.

I need to make some decisions on nutserts size. I don't like the smaller size included with the panel kit. 6-32. I'm going up to at least a #8.

  Mar 14, 2021     Avionics Install - (20 hours)       Category: Avionics

It's been a few weeks since I updated my build log! I have been finishing up little odds and ends with the engine install and have now moved on to the Avionics install. I've spent hours upon hours researching (since last year) the avionics package I want in the Highcountry Sportsman and finally decided on the following Avionics Package:

Garmin G3X with GNX375 GPS Navigator.
G5 Back-up
GTN 255 Comm/NAV
GTR200 COMM#2
507 Autopilot
GMA 245 Audio Panel

This seems pretty simple but there are so many decisions to make when designing the Avionics components. All items were ordered via ACS after talking with multiple sources. Avionics arrived over the past few weeks along with the Glasair Factory panel and glarisheild. I'm very pleased with the panel and glairsheild as these will help make the panel look very professional.

I've also been working on the various switches, breakers, and dimmers, etc. that all go into the panel. It can seem a bit overwhelming at times but just like building the wings....take it one step at a time!

I started to build the avionics trays and mounting the remote equipment this weekend so the install has begun. I need to order a few more small items but the majority of the $$ is done (at least I think so!).