Apr 27, 2023     Finished GPU installation - (1 hour)       Category: Avionics

The 1" 6-32 screws arrived from Aircraft Spruce (ordered some epoxy too) so I installed them, four washers on each screw to attach the GPU plug to the bracket. I moved the groundwire to the other side of the overflow bottle which is much better tested it out. Still a little weird with the G3X dimming when I turn on the avionics. Also when I turn on the master even though the battery isn't connected. I'll read up on things.

  Apr 18, 2023     Made a bracket for GPU - (2 hours)       Category: Avionics

I did my blood platelet donation and then stopped by the hangar to do a little cleaning and started looking at ways to brace the GPU plug. I had a couple of DG-14 Adel clamps so I made up a backing plate (which was included in the White Lightning installation kit that came with the unit but not with the $25 replacement kit) and finally got the plate secured to the engine mount. I'm going to reroute the ground wire to the other side of the coolant tank. I couldn't screw on the GPU plug itself because I don't have 1" #6 screws. God forbid they should include those in the kit.

  Mar 16, 2023     Wired up White Lightning GPU - (2 hours)       Category: Avionics

Finally got the White Lightning wired up. Nice little unit. Only thing I noticed is when I turn on the avionics, the display dims considerably (and stays that way) on the G3Xs (dual screen). The draw doesn't seem significant, especially since only the radio and xponder are added on the avionics.

  Mar 05, 2023     Mucking around the engine - (1 hour) Category: Avionics

While I was up in Vermont, the hangar flooded a bit since I wasn't around to shovel so went out a little bit today to start the cleanup, then got interested in moving a couple of small wires (to the battery contactor) because I didn't like the route I had. I went over the engine mount support instead. Not sure that's much better. But I added some spiral wrap.

For the White Lightning, I bought two battery cables from Van's. I'll hack one end off on each to solder on the connectors. I attached one to the battery contactor. But now, of course, I can't find the White Lightning connectors.

And finally, I saw a post on VAF with pictures of the engine installation and looked at my throttle cable route. I don't see how it doesn't chafe on the engine mount support tube. Will investigate maybe installing some clamp.

  Feb 06, 2023     Avionics are alive - (2 hours)       Category: Avionics

The temperature rocketed up to 34, so I headed to the hangar with no discernible plan. I tie-wrapped the heck out of the wiring behind the AV--6000 to tidy things up. I also added some spiral wrap to the wiring that branches off to the pitch servo because I was concerned it would chafe on the airframe and/or the fuel shutoff cable.

I looked at wiring in the White Lightning power unit to the battery contactor but it doesn't come up with any connectors to do so. So I decided it was time to attach the +/- cables to the lithium battery and fire up the avionics.

They came alive find. Not much is connected so the G3X has lots of error messages -- spar pins, canopy, AHRS etc. I haven't read enough, really about how the Rotax works so I just quickly flipped on the fuel pumps to see that they operate (they do) . I got a "fault" on Lane B on the ECU but I think it's probably too early to worry about that sort of thing. I still have some connections to make up front anyway.

The three green lights -- avionics master etc - on the switches do not light although the switches themselves are functioning.

[Update: The Lane B fault was no big deal. I had turned both on at the same time. Flipping A on and waiting and then Flipping B on worked. Engine data, such as it is, showed up on the MFD after I restarted it in config mode. And finally those green lights on the three switches ARE on; you just can't see them because of the placement of the switch]

  Jan 29, 2023     Ground power unit - (.1 hour) Category: Avionics

It's clear that there's a good sized learning curve behind the RV-12 avionics so I bought Van's' White Lightning ground power unit so I can sit in the plane and play with the avionics without draining the battery. The installation question is whether it should be wired to the output side of the battery contactor (I'm leaning that way) or the input side. With the output side, you can power the airframe without draining the battery because you don't turn on the battery master. With the input side you get the benefit of recharging the battery without turning on the battery master.

I'm reluctant to do that because I don't know enough about recharging issues for the EarthX lithium battery.

In any event, it'll be a bear to get access to either side of the battery contactor so it'll wait 'til warming weather. -8 this morning in Minnesota.

  Jan 25, 2023     Closed up the panel - (3 hours)       Category: Avionics

With the big wires grommets properly ProSealed, I did a final check of the wiring and added some spiral wrap in spots where I thought chafing was a possibility -- primarily the com antenna at the firewall (that connector really should be a right angle connector) and also some of the wires to the HIC modules area that I thought might contact the frame of the transponder. I also tie-wrapped a couple of spots. Then I reinstalled the upper fuselage skin (of course I'm short two plastic washers and I have to order some of the stainless 507 screws in a future Van's order).

And then I attached the second G3X. That done, I followed the instructions, put a piece of tape on the upper right corner of the G3X, reinstalled the canopy frame and checked for interference. Yep, it rubbed on both sides. So I filed and filed until it BARELY closes and open without hiitting but there's no way that's not going to rub slightly once the canopy is on. But I was mindful of the admonishment not to file all the way through the tube of the frame. How much is that? I don't know and didn't want to find out so once I got it to clear, I resigned myself to the fact there'd be rub marks on the upper outer corners of the G3X's, which there are anyway because that tape didn't protect squat. Whatever.

Finally, I cut the pitot lines where they meet and connected them with the quick connect FLF00023. Seems to me where that come up from the tunnel could be a chafing point; not sure how to protect that.

The other thing I have to figure out is what to do with all the extra wire from the trim servo.

I have a ground power unit on the way so I don't wear down the battery when testing everything out, and I'm awaiting a Halotron fire extinguisher before I power everything up. The regular ABC fire extinguishers destroy electrical equipment and aluminum.

[Update 2/4] Needed, ordered, and received more AN507C832R8 screws and a couple of black washers for the upper fuselage skin and instrument panel. It's funny how hardware walks away after inventory.

  Jan 20, 2023     Sealed wire pass-through - (.2 hour)       Category: Avionics

I mixed up some ProSeal, jammed it into a syringe, then drove to the hangar to better seal the two rubber grommets with ECU and GPS wires. I ProSealed the passenger-side grommets after the pass through was less than sturdy after a previous session in which the engine side only was ProSealed.

  Jan 17, 2023     Nutplate for fuel inspection cover and installed AP head - (2 hours)       Category: Avionics

Hadn't been out to the hangar in awhile other than to shovel snow and when I arrived today a bunch of snow (very heavy) fell off the roof so I had to shovel that out so the hangar doesn't flood. More to come tomorrow, I suspect. It's coming into the hangar but, so far, not as bad as last year.

One of the things I wanted to do today is add a new nutplate to the fuel cover. You may recall that, as designed, the nutplate is DANGEROUSLY close to the fuel line, especially the old design lines. I had earlier removed it. (See August 25, 2022 entry). So I added a new one and then took some firesleeve and ziptied it to the fuel line which rests almost on the bottom skin. In the spring I'll put some blue RTV in there.

I also added the head for the autopilot and test fit the MFD. I have to reinstall the top cover in order to screw both Garmin G3X in but I still want to load up a syringe with a bunch of ProSeal to cover the wire grommets on both sides first.

I also removed all the spark plugs and shot some oil fog in each cylinder to prevent corrosion. I put the spark plugs back but they are not torqued

  Dec 16, 2022     Prepped panel for MFD - (1 hour)       Category: Avionics

Some of the section of the KAI on the dual G3X display aren't particularly complete, especially if you have the extra-spendy silk-screened panels. In one section it tells you to countersink holes that don't need to be countersunk and in another is doesn't tell you to countersink holes that do need to be countersunk. So the only real way to identify the countersinking is to put the panel section on and put the G3X in and see which holes it's covering. Those are the ones that need to be countersunk.

So I did that over a couple of days, bringing the panel home to do the task, and then I reinstalled it and test fit the G3X. I haven't yet permanently put it in because there's a few things I want to do before closing things up. Some wire wrap arrived from Aircraft Spruce that I'll use to protect some areas that I think might be chafe prone.

SCREW pan HD 4-40 5/8 came in a Van's order along with some heat shrink.

I also still need to install the autopilot control head.

BTW, I've given up trying to fit the harness in those plastic doohickeys down near the fuses that Van's wanted installed. They're just not big enough and it's just a really, really crappy design there. I would much rather have put some Adel clamps in. I'll probably leave the plastic junk in and tie wrap it "closed" around the wires.

That's another area where chafing concerns me because of the metal throttle and fuel shutoff cables that share some of the space. I may wrap some "rescue tape" around the wires. We'll see.

  Nov 15, 2022     Removing AMP connectors - (.1 hour)       Category: Avionics

After testing out various options to removing the AMP connectors on the wing route housing and considering other alternatives to buying a $157 tool from DigiKey, I decided to buy the $157 tool.

After today's funeral for my friend and former neighbor, Hadley Bakker (ALS sucks!), we stopped by the hangar briefly to test it out.

I don't remember what sex was like, really, but it must've been like this.

  Nov 12, 2022     Cleaning up things in the tail cone - (1 hour)       Category: Avionics

I crawled back into the tailcone and removed the loose zip ties and zip tied the pitot tube, static port tube and magnetometer wiring inside the J-channel. Not fun for a guy with Meniere's Disease. I'll put some RTV in places where they exit the Z-channel.

While I was there I also attached the XM Radio antenna cable to the Garmin router.

Earlier I added more zip ties to the panel wiring as well as to the big cables that go to the Engine Control Unit.

I have to mix up some ProSeal because of those grommets popping out.

  Nov 10, 2022     Discovering errors - (2 hours)       Category: Avionics

I realized today that I didn't install the transponder. I went back and looked at the instructions which said to install the backplate must missed AND THE TRANSPONDER. So took the top skin off again and did that (and discovered a screw on the backplate I hadn't tightened). But in the process of moving the big cables around, those ProSealed grommets are still coming out of the hole. I really hate the split grommet method Van's uses. I'll have to research more but I'll probably have to put ProSeal on the interior side.

The instructions seem to show the top skin being off for the installation of the PFD (the GDU 460) so I took it off -- again!! -- and started putting the screws in but there's nothing to hold the top left screw. So I asked Van's support and got my "duh" moment when Eric reminded me that I'd added a single lug nutplate (you know, the ones that took three weeks to get?) to the top skin frame. But when I took the top skin off, of course the platenut in that spot disappears. Like I said, "Duh!" I feel like my cognitive skills were better when I started this project.

Anyway, I also installed the radio.

I'm trying to keep things from looking like a rat's nest back there but I'm not sure I'm succeeding.
Now, then, for the problem.

While removing screws in the panel skin -- a boring task -- I just sort of gazed around taking stock of things when I noticed that there are 4 open rivet holes in the center spar carry-through under the fuel tank. No clue how that happened. So I'll have to remove the fuel tank and squeeze those.

I don't know how I missed it but I went back to the plans (20iS-U_12iS page 5 & 6) and these require AN470AD4-8 rivets. I must've gotten distracted. Bad thing.

(Update: Went back and looked at the builder log entry for 12/12/17 and I had noted that I couldn't finish four rivets because they were in a big that was backordered from my fuselage shipment. There's no way those rivets are going to be around anywhere now so I'll have to order some more)

  Nov 10, 2022     Fitting panels - (2 hours)       Category: Avionics

Did some more cleaning up of wiring then began fitting panels. Added the ignition module, ELT remote (after buying a Lithium battery that supposedly will last 10 years) and the backup battery switch then screwed it to the frame. Looks good.

  Nov 07, 2022     Sealing grommets - (2 hours)       Category: Avionics

I took the top instrument panel skin back on, made sure all the connections I needed to make were made, then took off the electronic fuse box, mixed up some ProSeal (neat trick when it's 37 degrees), and sealed up the three grommets with wires to be sure any gasses don't come into the cabin. I also home it will help hold the split grommets in place because it's not a good system. When I built the RV-7A, I used some nice stainless steel firewall passthroughs but Van's has this more rinky dink method.

I also reinstalled covers in the baggage area, though I'm sure they'll come off again.

I worked some more on trying to get the wires out of the wing connectors so I can replace them. It's slow going. With the various tools I have for accomplishing it, I've been able to get only two out thusfar. I dropped a note to SteinAir to see what tool they use.

  Nov 06, 2022     Installed platenuts for instrument panel - (2 hours)       Category: Avionics

The order for platenuts from Aircraft Spruce arrived two days after I ordered them (first class). Meanwhile, Van's finally got around to telling me the power supply was backordered - big shock. So I canceled that and told them just to send the hardware which they did. Advantage: Aircraft Spruce. Van's customer service is the worst I've seen since 2001.

It shouldn't take two hours to install four or five platenuts but it did because of the convoluted way they have to be match drilled. I marked the interference spot in the passenger-side panel, removed the plate and filed it away and then installed the platenuts after drilling out one hole to #27. Deburred, dimpled and riveted them in place. I'd already drilled out one platenut on the pilot side but needed to match drill for the platenuts there and I did that, deburred, dimpled, and riveted them in place.

I found one interesting thing. In the instruction for the right side for the Dual Garmin G3X, it says you need to countersink the attach holes - something like 47 of them I think. The nice silk screened and powder coated blanks, however, do not come countersunk so I suspect they're using different hardware to attach those. I'll have to check with Van's.

  Oct 23, 2022     Tidying up some wiring - (1 hour)       Category: Avionics

There's not too much I can do until I get the right set of screws to add connectors for both the COM radio and XPNDR but I did a few steps. First, I confirmed the location of the AOA port hole in the left wing but will wait to work on it until someone can help me lift it onto the workbench.

One of the things I like about the Van's store is you can download all of the plans for my project and the pictures are in color and are a heck of a lot better than the black-and--white pictures in the printed KIS that they send you.

For example, Step 3 of 42NiS-16 says "Gather the WH-00134-1 near the inboard aft corner of the ES CPU Fan using the clamp as shown and install the clamp
onto the F-01202B-1 using the screw called out in Figure 1." OK, but there's a LOT of wires there coming from all sorts of different directions. Which ones go in the clamp exactly. Couldn't tell from the printed version but the color picture makes it more clear. The ones coming from the engine compartment do not. The ones coming from the GEA 24 do. Cool.

I bundled them up as instructed. It bothers me a bit that the wires from the GEA 24 are sitting roughly on the cooling fan but I guess I'll address that later. I also want to add the antenna cable and try to reduce that bend in the DSUB connection to the GPS-20A

I also drilled out the left side platenut (per 42NiS-17) and added a #27 hole (still have to do the right side). Single-lug platenuts go here and I don't have any. So I ordered some from Van's and also added a few mounting screws and other hardware called out in the coming steps, figuring I'll lose one or can't find one in the stash sent to me. Plus if Van's says install 19x screws; they give you 19 screws; no more, no less. So there's no room for error.

At the same time, I also ordered the Power Unit featured on the website, which will allow me to power up the electrical system without draining the battery. I figure I'm going to have learn all about the G3NX by sitting and playing and this will make that more functional.

  Oct 22, 2022     My kingdom for a screw!       Category: Avionics

It seems likely now that SteinAir forgot to include the assembling kit(s) for the backplates on at least the Garmin remote transponder. The backplate was tossed in a big but there should have been screws for the connectors. I searched everywhere and found none but at least I sorted out a bunch of hardware bags into the appropriate trays while waiting for the last camper rental of the season to return.

A person on Facebook is going to send me the screws so I can move forward. Had some communication with SteinAir but it was a Friday afternoon and I don't know what the resolution will be if any. What other kits need to be ordered? No clue.

  Oct 20, 2022     Installed transponder bracket - (.2 hour)       Category: Avionics

The little racheting screwdriver I ordered arrived so I rode the E-bike over to the hangar and it worked fine. It's the only way to tighten four screws that hold it into place. I assembled the 115-01879-00 GTR 200 Backplate and 37-pin d-sub connector labeled "COM" from the WH-00134-1 RV-12iS Garmin Common Harness (VFR) because it was already attached to the bracket.

I wanted to connect the d-sub connector labeled "XPNDR" and the BNC connector labeled "XPNDR" from the WH-00134-1 to the 011-02976-00 GTX 35R Backplate Assembly but I don't know what hardware to use. I'll consult the installation manual.

I connected the 9-pin d-sub and BNC connectors labeled "GPS" from the WH-00134-1 RV-12iS Garmin Common Harness (VFR) to the GPS 20A . And I connected the 15-pin d-sub connector labeled "BATT" from the WH-00134-1 to the IBBS-12V-3AH .

  Oct 17, 2022     Putting stuff back together and installing more avionics - (3 hours)       Category: Avionics

I bought the optional CO2 detector a few months ago but the instructions made no sense as they referenced different installations but now that I've been installing some of the avionics, it made a little more sense. Basically it involved crimping on some DSub pins and mounting the unit. I finished installing the G20A and then added the backup battery. I ended up removing the battery harness from that big bushing and looping it around the frame I just installed. I like that better.

Still trying to figure out how to tighten those screws in the transponder bracket without being able to get a screwdriver in there.

I also remounted the ROTAX fuse box.

  Oct 16, 2022     Installed GEA 24 - (1 hour)       Category: Avionics

I mixed up a little ProSeal and put a thin coat on three holes where the GEA 24 Engine Indication System and F-00145 GEA24 Adapter Plate mount. This is a little strange because it mounts with four holes. Why doesn't the 4th hole get ProSeal? I wonder if it has something to do with grounding?

Anyway, after doing that I installed the four screw heads and tightened everything down. I had to remove the cooling fan assembly yet again.

Then I put ProSeal on all four of the screw heads on the forward side of the firewall.

I think I need to go back now and take a look at the CO2 detector installation as I think the instructions will make more sense to me now that I know what all the various Garmin numbers are. Might be a good time to go ahead and install it.

  Oct 15, 2022     Installed GTR 200 and GTX 35R racks       Category: Avionics

My order of hardware came in from Van's so I organized it and installed the racks, only to find I'd put the GTR 200 rack in upside down. Fixed that and put the GTX 35R racks but the screws are inaccessible to tighten. Will research.

  Oct 01, 2022     One step back - (2 hours)       Category: Avionics

I'm very late in the build so the number of parts, including hardware, is dwindling. In this session I found that the amount of hardware is dwindling too much.

I got started on building the GTR 200 AND GTX 35R RACKS (Section 42Nis page 12) but immediately ran into problems find the correct hardware. Where it goes, I don't know. But I didn't have enough AN507-632R8 crews or MS21042-06 nuts to complete the rack. So I jumped ahead to 43CiS_12iS, the dual G3X instructions and prepped up the flange doubler only to discover I have a shortage of MS21051-L06 nutplates. So I ordered one along with some additional hardware, bringing progress to a halt for now.

The order:
AN507C632R8 - Flat Head Screw (non structural)
6 $0.48
NAS1149FN632P Flat Washer
15 $0.60
MS21042-06 Metal Lock Nut
8 $2.80
AN525-10R8 Washer Head Screw
4 $0.80
NAS1149F0332P Flat Washer
20 $0.60
AN507C632R6 - Flat Head Screw (non structural)
8 $0.64
AN525-10R7 - Washer Head Screw
12 $2.40
MS21042-3 Metal Lock Nut

In writing this update, I have also realized that the dual G3X also requires two MS21051-L06 to be installed in the upper flange. Do I REALLY want to put yet another order in for just two stinking nutplates? I do not. Anybody got a couple?

  Sep 30, 2022     Building supports for COM radio - (1 hour)       Category: Avionics

I haven't been out to the hangar for a few days because we have had visitors at the house, and I also had to do a thorough cleaning of the camper when it came back from a rental in a disgusting state, but I took a few minutes to rivet in the forward support brackets for the COM radio, and also added the snap bushing for the wiring supports on the left and right side. Not sure all the wires I ran through them are supposed to go through them but we'll see.

Time to start moving some of the avionics out to the hangar.

  Sep 25, 2022     ProSealed rivet heads - (.5 hour) Category: Avionics

Per KIS Section 42NiS-11 Step 4, I mixed up some ProSeal and lightly covered the rivet and screw heads on the forward side of the firewall.

  Sep 23, 2022     Finished firewall drilling - (3 hours)       Category: Avionics

After a dentist appointment for some sensitive teeth, went back out to the hangar with a revised strategy for drilling - being even MORE careful to turn the drill slowly. Result: not much difference. Funny thing: the three or four brand new #30 drill bits still took about 15 minutes per hole. But the old Harbor Freight bits for the #11 match drill instruction took a little over a minute and made a decently round hole. In any event, the job got done.

Then I riveted the F-00055-L-1 & -R-1 GTR 200 Support Brackets and the F-00054-L & -R to the F-01202B-1 Panel Base and I was sure to place the manufactured rivet heads below the subpanel shelf, but then I realized I'd again made the mistake that *I* was the one manufacturing the head (no, Bob, that's the "shop head"), so I drilled them all out and installed them correctly.

I riveted the F-00074-L-1 & -R-1 Garmin Xpndr Firewall Brackets to the F-01201A-1 Firewall Top, placing the manufactured rivet heads on the forward side of the F-01201A-1. So I got it right that time.

Access is pretty limited in the front so I had to pull some wires back around the GPS antenna shelf, which caused the two split rubber grommets to fall out. Putting those back was a blast.

Next time I'm out at the hangar, I'll mix up some ProSeal to cover the rivet heads.

I wonder if it's OK to reinstall the fuse box.

  Sep 22, 2022     Firewall drilling - (1.5 hours)       Category: Avionics

Had to get to the hangar early for a camper rental dispatch so did some more work with the drill guides for the G3X. I took the top skin off for access, drilled out three rivets on the battery cage, attached a drill guide there and match drilled #30 holes.

Moving over to the F-00074-L-1 DRILL GUIDE, progress was much slower. I got one or two holes drilled - eventually -- but the work hardened and progress was non-existent. I got frustrated so gave up for the session.

  Sep 20, 2022     Prepped more G3X pieces - (1.5 hours)       Category: Avionics

The day started with a nice surprise as Dave Hirschmann of AOPA stopped by. He's in town to get checked out in Mark Baker's Caravan so I assume he's going to make a ferry flight.

Otherwise I added nutplates to the F-00054 brackets then cut out the drill guides for the firewall piece. I had to take the Rotax fuse box off the firewall and also removed one of the fans from the subpanel floor in order to get at some holes that are going to be match drilled. The F-00074-L drill guide didn't fit quite right so I had to modify it a bit. I'm sending Van's support a note to be sure I've got it in the right spot.

  Sep 18, 2022     Prepped G3X brackets       Category: Avionics

I finished riveting the doubler to the instrument panel flange (I really should work on the second one but that's in a different section) and then dug out various brackets needed for the fireall. This mostly consisted of cutting to separate and filing/deburring, countersinking, and attaching nutplates. This included the firewall bracket, the transponder bracket and the F-00054 brackets.

I've decided not to replace the center console. Too much can go wrong detaching the various cables and it looks fine as is.

  Sep 18, 2022     Added instrument panel doubler - (1 hour)       Category: Avionics

It doesn't look like the temperature is going to warm enough to drill the rear window until next year so I've circled back to continue the Section 42NiS installation of the Garmin G3X touch display. The instrument panels are backordered and Van's reported that as o 9/1, they are "overdue." Yeah, no kidding.

I didn't do a lot -- didn't have time because of grandparent duty -- but I match drilled F-00063 flange doubler, countersunk the appropriate rivet holes and clecoed the nutplates on. But riveting will have to wait.

  Sep 16, 2022     Moved autopilot servo ground wire - (.2 hour) Category: Avionics

I only had a few minutes because people were coming to pick up the camper for the weekend but I moved that pitch server ground wire from the rib to under the nut on the servo itself as Van's recommended.

  Sep 15, 2022     Installed autopilot pitch servo - (1.5 hours)       Category: Avionics

First an update on installation of the roll servo and the questions I had, which have been answered by Eric Rushting at Van's. The plans show a zip tie through the lightening hole in the servo bracket. That keeps it off the fuel shutoff valve. Also the ground wire is attached on the nut side of the most aft bolt on the left side. I tried getting a little more slack out of the harness but it's pretty tight. Something to keep an eye on.

Moving on to the pitch servo, it's a tad more straightforward, at least insofar as getting the DSUB connector through a slot. I mounted the servo after attaching the pushrod to it, then attached the push rod to the the tab on the control column. All good. I didn't put torque wrenches on most things but I pretty much know what 25 inch pounds feels like.

Earlier in the avionics instruction, it said to attach the ground wire to a rib. In this section, however, it says to attach it to a screw and nut on the servo. I emailed Van's support for clarification as I'd already attached it to the more outboard rib.

I added the protection on the cutout where the dsub went through the rib but I really don't like how it sits. I think I'll add a bunch of RTV there.

The section in the instructions notes how critical the autopilot disconnect switch is but apparently the backordered silk-screened instrument panel pieces includes the center console which I had installed. So I'm debating taking that out which will require a fair amount of work since I already installed the control cables. That includes the long one to the fuel shutoff and the short one to the engine throttle. Do I really want to do that just to make the center console pretty? Probably but I don't want to do it right now. And, frankly, I may not do it at all.

[Update] From Tony Kirk at Van's:

Hi Bob,
L6341 is a ground wire for the wingtip lights on a Dynon system. If you are installing a Garmin system you won't have this wire.
I would install the servo ground as per 44BiS/U-04. It probably doesn't really matter though.
Thanks,Hi Bob, L6341 is a ground wire for the wingtip lights on a Dynon system. If you are installing a Garmin system you won't have this wire.I would install the servo ground as per 44BiS/U-04. It probably doesn't really matter though.

  Sep 14, 2022     Installed autopilot roll servo - (1.5 hours)       Category: Avionics

The Garmin roll servo for the autopilot was installed according to the KIS, but I noticed a few things:

1) there's a ground wire with a ring terminal . Didn't see it mentioned in the KIS.
2) The wiring pretty much sits on the fuel shutoff valve mechanism. That needs to be protected.
3) The servo comes with a safety bracket kit. Nothing in the KIS about it.

Have submitted to Van's.

  Sep 12, 2022     Autopilot pushrods - (2 hours)       Category: Avionics

With the installation of the rear window on hold, possibly until next summer, I've moved on to other things that need doing and this seems like a good time to install the servos for the dual axis autopilot (Section 44BiS). I started by cutting the F-1291 Roll Servo Pushrod and the F-1292 Pitch Servo Pushrod from AT6-058X5/16 Tube (4 11/16" and 4 1/2"), then drilled and tapped both ends of each with a #3 drill bit and a 1/4-28 tap.

I then assembled the F-1291 Roll Servo Pushrod and hardware and F-1292 Pitch Servo Pushrod hardware.

  Aug 23, 2022     Prepped top baggage skins - (3 hours)       Category: Avionics

Given how much downtime I had over the year waiting for the avionics kit, wouldn't you think I would've used that time to prep and prime the F-01277-L-1 & -R-1 top skins that go over the baggage compartment attach to the tail cone? Of course you would and, of course, you would be wrong. So I deburred both skins, finished off the edges and then cleaned and primed the inside portion.

I just couldn't get the gun settings right for a smooth finish -- too much pressure I think -- so the surface is "sandy." But then I decided I like that because it should deaden the light and prevent any glare.

The holes don't quite line up on the right side F-01277 rollbar brace and I'm not sure why. I get a little pillowing when clecoing that little "triangle." So I'm going to just open up some of those holes a bit to flatten it out better.

  Aug 22, 2022     Added chafing prevention to ADS-B IN antenna - (.3 hour) Category: Avionics

I stopped at the hangar on the way home from a long day at Target Field just to add a dab of blue RTV to the chafing protection of the ADS-B IN antenna cable and zip tie it to the stiffener. Of course it was ugly crawling in and out with oozing blue RTV on my fingers and getting it on my eyebrows (!) and fingers. It didn't hold the plastic stiffener liner in place very well and kind of looks like a murder took place.

  Aug 19, 2022     Installed ADS-B IN router - (2 hours)       Category: Avionics

I riveted the ADS-B unit bracket in place (pretty cramped in there so I put a fan in the tailcone). Then attached the unit and connected the D-SUB connector. I drilled a 1/2" hole 2.5" forward of the rivet line on the bulkhead and installed the rod antenna. Got it pretty tight but probably need a second person to hold a wrench on there sometime. I ran the antenna wire into the J-stiffener channel and connected to the ADS-B IN port. I need to get some blue RTV to glue the cat channel in place for chafing protection. Once that is done, all steps in Section 53 will have been completed.

I also found the adhesive velcro to went back to the final steps of Section 42 (Common) and attached the holder for the spare fuses. That officially concluded everything I had to do in Section 42 (Common) although I'll doublecheck to be sure.

  Aug 17, 2022     Reinstalled fuel cutoff cable; Began ADS-B/XM installation - (2 hours)       Category: Avionics

I tightened the nuts at both ends of the fuel shutoff cable, then reinstalled the connection, making sure the cutoff lever was 1/4" above the deck, confirmed the full rate of travel back at the valve then tightened the allen nuts. The instructions say to tighten the bottom first then evaluate full range of travel. You can't do that because the B nut on a fuel line is in the way. So I had to do the top first, move it, then the bottom.

After that I added nutplates to the ADS-B IN/XM receiver bracket, mounted it (I had to drill out one rivet on the baggage bulkhead, and match drilled four vertical holes. I'll rivet it in place later in the week.

  Aug 12, 2022     It's time to put tailcone on - (.5 hour)       Category: Avionics

I brought the GSU 25 out to the hangar and installed the fittings but the directions then tell you how to snake three separate lines -- AOA, static, and pitot. First, I found that when I made an AOA line weeks ago, I actually had already made one (a retrofit came with the avionics kit so I must've made one in the instructions when working on the fuselage. Who knows?). There were also confusing instructions about the pitot and the "aft garmin" line being born from cutting the former. That's a clear "time out" signal for me. I need to connect things and see what goes where so it's time to put that tailcone on.

Yes, I'll be doing some work in a confined space (ADS-B installation, for example) but putting the tailcone on now gives me a good frame of reference for moving forward rather than working around things being apart.

  Aug 10, 2022     Not much of anything - (.1 hour)       Category: Avionics

I looked around in the closet where I'm storing the avionics for the GSU 25 to no avail. Went out to the hangar (basically to catch a bus into St. Paul to have lunch with a friend) then looked at the KIS to see if there was anything I could do without the GSU 25 and the answer is "not much". So I added an tie-wrap standoff to the baggage bulkhead.

Nick at SteinAir had given me a hint as to what the box looked like with the GSU 25 and once he did, I knew were to look. So I pulled stuff out of the closet near where I would have put the thing and there it was. It had fallen behind something else.

  Aug 09, 2022     Installing equipment in tailcone - (2 hours)       Category: Avionics

I found a cable that does essentially the same thing as what is depicted in the Van's KIS figure regarding the ELT remote cable connection; it just isn't exactly as depicted. So I made that connection. Also installed the GMU 11 (magnetometer) on its bracket and installed the unit on the bracket in the tailcone. I did not connect the DSUB connector. I'll crawl back in there to do that once the tailcone is attached.

I have not yet found the GSU 25 -- ADAHRS -- in my stack of boxes that I've kept at home (until the new insurance kicks in at the hangar in a couple of weeks; I raised the value to $90,000) . I'll keep looking.

  Aug 08, 2022     Finished installing wiring bushings - (3 hours)       Category: Avionics

Another one-step-forward-one-step-back day. I finished installing the bushings on the wires running aft. I can't say it was the most fun I've ever had. I had to disconnect the cable to the fuel shut-off valve in order to -- I thought -- route that through the bushings . Turns out, apparently, it doesn't go through the bushings at the front. Anyway, while trying to figure out why the cable was no so stiff when I attempted to move it, I apparently pulled the thing out of its seat up front and couldn't get it to budge. So I took the whole thing off. Still couldn't get it to budge. Ordered a new one from Van's -- $145 -- then I got it to work. Oh well. Better to have a new cable, I guess.

The instructions said to connect ELT remote cable to an ELT audio cable and provided a really poor picture that doesn't seem to reflect my harness. So I have to do some research on that.

Also, I need to see how everything is secured going through the baggage bulkhead.

Other than finding some adhesive velcro, reinstalling the fuel tank, and figuring out that ELT connection, Section 42 (common electrical) is more or less complete.

  Aug 07, 2022     Installing bushings - (.7 hour)       Category: Avionics

I rode the new E-bike out to the hangar and it was a little later than I thought because I needed to be back home in an hour to help take care of Dex. So I started installing bushings in the wiring. How hard could that be? Hard. Really hard to get all the wires in the slit bushing and then get the bushing into the bushing brackets. I ended up doing four bushings in 45 minutes. It'll get easier as I work my way back in the fuselage as there are fewer and fewer wires.

  Aug 03, 2022     Crimped on connectors. Added Bushing brackets - (2 hours)       Category: Avionics

Back at it after 5 days at Oshkosh and a few Twins game. Rode the new E-bike over to the hangar. Sweet! Bushings came from Van's for that cabin/rollbar lighting and canopy switch. $5 for a 12 cent bushing. Crimped on the connectors that came from SteinAir to the wing pin switches and did a little research to be sure I got them right. Then prepped and riveted on the four brackets that will hold the bushings/wires on the forward ribs.

At Oshkosh, bought cobalt drill bits at Aircraft Tool Suply ($14)
Bought logbooks ($20)

  Jul 24, 2022     Connected ELT, ran cockpit lighting wire - (1 hour)       Category: Avionics

The mystery ELT wire was solved when I removed the unit and found that it has been buried underneath it. So I connected the wire to the harness and reinstalled, then used a couple of tie wraps to secure all of the extra wire to the harness.

The lighting wire presented another mystery. First, I drilled a #12 on the underside of the rollbar, then ran the two wires (a white one and purple/brown one; L6028 (YEL/PRP) and GARMIN: F7139 (WHT)] But the plans say there's a twisted pair with L6029 (YEL/GRN). I have no idea where that one is but it's not in the harness as near as I can tell. I'll figure it out after Oshkosh.

And I'll have time to study because the plans call for a snap bushing -- SB 187-2 -- which appears to have been shipped with the finishing kit. I found the bag it is alleged to have come in. No snap bushing. Do I REALLY want to pay shipping to have one stinking snap bushing sent from Van'. No, I do not. I'll look for one at Oshkosh. But I can't do any more work on 42MiS/U-27 until these issues are resolved.

  Jul 23, 2022     ELT, Fuel pumps, ADHRS et al connections - (1.5 hours)       Category: Avionics

We're nearing the end of the journey to the aft portion of the plane in this portion of making connections from the wiring harness.

Routed the Roll Servo Connector through the F-01206H-L-1. Secured the connector clear of flight controls with a tie-wrap until the optional autopilot is installed.

Routed the ADAHRS connectors through the F-01206H-L-1 .

Routed the Fuel Pump 1, Fuel Pump 2, Fuel Pressure Sensor, and Magnetometer (Garmin) connectors through the F-1207C-L and into the tailcone. I notice I seem to have a LOT of trim wire.

Removed the tape covering the aft-facing port on the FLF-00013 adapter, then installed the fuel pressure sensor and then connected the fuel pressure sensor connector.

Installed the fuel pump power connectors and took pictures and doublechecked to be sure I got the right wires to the correct fuel pump.

Routed the magnetometer wire into the tailcone and temporarily secured with tie wraps. One of these days, I'll get some help to permanently install the tail cone.

Routed the right spar pin switch, the cabin light, and canopy latch switch wiring as shown in Figure 1 on 42MiS/U-26. Found out why the aft hole is used heere. The fuel vent line will pass through the forward hole. Used a tie-wrap to secure the wires and the ELT antenna cable to the ES-00301 on the F-01223-L-1.

Didn't connect the W6075 (BRN/BLU) spar pin switch wire spade terminal to the outboard "COM" spade of the ES E22-50K-1 yet because the new spade terminals are due from SteinAir on Monday.

Route the E-04.10.5 ELT Remote Cable to the ELT Audio Alert following the path of the Main Harness down the right side of the aircraft. Connected the male RJ-11 connector on the ELT Remote Cable to the ELT Audio Alert. I couldn't find the ELT DIN connector that I'm supposed to connect together with the wire/connector coming down from the harness but now that I think of it, it's probably in the ELT box.

Routed the ADS-B IN Connector through the F-1206A-1 and F-1207C-R, and secured the wires to the ES-00301 on the F-01206A-1.

  Jul 22, 2022     Snap bushings and wire routing - (1.5 hours)       Category: Avionics

I was able to last at the hangar until the temperature hit 92. I routed the fuel sender wiring on the left side and secured the wires loosely (for now) to the tie clips I riveted on yesterday. I cut the terminals off the spar pin wires to get them through the snap bushings I'd mistakenly put on. SteinAir order is on the way and I'll crimp new terminals back on.

On the right side, it's interesting to me that the wiring comes up through the aft hole, not the forward hole (like on the left side) of the baggage floor. I wonder why? In the process of routing the spar pin wire, I notice I'd neglected to enlarge the hole (to 5/16") just aft of the microswitch. I had to take the switch off to get in there with a step drill. Then installed snap bushings. I'd already cut the terminals off like on the left side and will also crimp new ones on later.

I installed all the snap bushings per 42MiS/U-23 Step 6.

Secured the spar pin switch and fuel sender wiring to the ES-00301 on the left side. Pretty loose there so I'll probably add a dollop of blue RTV.

And I routed the COM Antenna Coax Cable through the center section bulkhead and attached the COM BNC Connector to the AV-00008 COM Antenna per 42MiS/U-24 Step 2. I'll keep an eye on possible interference there with a brake line.

  Jul 21, 2022     Two steps forward. One back - (.5 hour)       Category: Avionics

It's like the stock market these days. You have a really good day and the odds are you'll get hammered the next. I continued on today by drilling out two rivets in the rollbar brace and attaching tie wrap clips and reriveting, then snaking the fuel sender signal wires up through the floor board. But the two wires for the spar pin alarm, with connectors crimped on, wouldn't go through the snap bushings. Why the hell did I put those snap bushings in. Rather than fight to get them out of the holes, I ordered new connectors from SteinAir and, probably after Oshkosh, I'll cut the old ones off, run the wires, and crimp new ones on.

  Jul 20, 2022     Flap motor wiring - (3 hours)       Category: Avionics

A good, long session (for me, anyway) at the hangar today. I did some more doublechecking and noticed the wing wiring connector differences so I figured out which way is up on both sides. Also ordered new connectors to replace the ones on the wing. They got damaged in installation and I figured I might as well do them right.

So I screwed the connector brackets on after installing the O-ring in the AOA housing and then prepped up the covers on both sides. I will wait until later to add Loctite to the screws. I secured all wires to the headsets and wing roots to the appropriate standoff on both sides. In installed the HW-00004 standoff for flap wires.

I disconnected the ES SW K2-AGPAAAAA Flap Switch from the harness, then installed the ES SW-807038-1 Switch Gasket and ES SW K2-AGPAAAAA onto the F-01246 Tunnel Cover. Reconnected the spade terminals once the switch was installed.

I connected the ground ring terminal to the seat rib.

I crimped on connectors to the flap power and signal wires as instructed then connected them to the flap power switch. I secured the wires with tie wraps. I couldn't tie wrap the extra wire length to the flap motor because I couldn't get a tie wrap under it. I'll do that later.

I installed the USB Dual Panel Jack onto the F-12101 and connected the wires to the appropriate spade connectors as shown in Section A-A. I then reinstall the F-12101 tunnel cover.

  Jul 20, 2022     Installed headphone jack and wing connectors - (1.5 hours)       Category: Avionics

The SteinAir shipment arrived (half of it anyway) with the isolating washers so I installed the pilot and co-pilot headphone jacks couldn't get them very tight using just finger (tough to access) so I'll look at getting a wrench in there. I was able to find an extra set of step isolating washers and isolating washer in my electrical "junk box" from the RV-7A project.

Then I attached the wing connectors to the left and right side although there is no guidance on orientation. I need to replace the corresponding wing root connectors (the male tabs broke off when fitting the wings) so I'll just make sure they correspond pin number to pin numbers.

(Update: Bought new wing connectors)

  Jul 19, 2022     Connections to stick grip, installed OAT - (1 hour)       Category: Avionics

Stein is sending isolator washers for the headphone jacks but they won't be here until Thursday so I moved on a bit in Section 42, installing the Garmin OAT probe and attaching its ground wire. I installed the wire standoffs on both sides (Per 42MiS/U-19 Step 4), connected the Pilot Stick Grip connectors through the d-sub shaped cutout in the F-01215-R-1 Seat Rib, Secured the left wingroot and pilot stick grip ground ring terminals to the F-01215-R-1 and L-1. I also secured the pitch servo connector with a tie-wrap until the Autopilot System is installed. And, finally, I tapped 8-32 the four holes in the F-00034A and F-00034-R Wing Electrical Brackets as shown in Figure 1 on 42MiS/U-20. I then brought them home for Alumiprepping and Alodining.

The CO2 system showed up. Instructions look pretty bad but I'll get around to installing it shortly.

  Jul 13, 2022     Finished routing main harness - (.2 hour)       Category: Avionics

I've returned from two weeks vacation in Vermont, working some Twins games and had a few minutes after today's game so stopped by the hangar to route the the co-pilot side wiring harness. Nothing connected yet.

I've also determined the problem with the autopilot connector is the labels on the connector housing was reversed.

Lockwood Aviation sent the replaced fuel pumps and the assembly back. I made a record of their serial number for future reference.

  Jun 25, 2022     Routed wires on the pilot side - (1.5 hours)       Category: Avionics

Pulling the wiring harness through all the small cutouts in the aluminum. Had to stop the other day because my hand was bleeding all over the place. Used gloves today and finished the routing on the pilot side before vacation.

The only problem I had was the connector labeled "pitch" in the instructions is labeled "roll" on the connector for the autopilot. Mislabeled connectors? Message in to Van's

  Jun 21, 2022     GPS/XM wires routed - (1 hour)       Category: Avionics

Because it's so hot, I can only work in the hangar for about an hour in the morning, but today I routed the GPS and XM coax through the opening on the right side of the firewall, attached the cover plate, and then added the modified grommet. They're a pretty big pain in the neck and I doubt their ability to withstand vibration, even with the ProSeal around it but we'll see.

I looked at routing the fuselage wiring but noticed I have to disconnect the autopilot switch because of the way the wires were routed and I decided to do that later.

I also attached the battery fault wire (those connectors do not like each other and zip tide that wire along with the coax to the bit Rotax ECU wires for stability.

Hearts are heavy here because longtime companion Lucie is not doing well and the end may be near

  Jun 20, 2022     Secured fuse block wiring - (1 hour)       Category: Avionics

I added two Adel clamps to secure all wires to the engine mount. Glad to have the Adel clamping tool I bought when I was building the RV-7A. It allowed to line up the holes so I could safety wire each closed, which made it much easier to get the screw and nut in place to hold them both. Then I zip tied the wires for additional stability and adjusted the grommet. I still need to mix up some ProSeal to seal the gaps in the grommet.

  Jun 18, 2022     Attached Generator A grounds - (1 hour)       Category: Avionics

Tony Kirk at Van's suggested just taking the Rotax fuse box off the firewall to get at the impossible-to-reach bottom part where the Generator A ground wires get attached. There are several lugs under there so I looked up which block I should use in the Rotax installation manual, but I also saw that all the ground lugs on both the A and B are interconnected with the other. As long as you don't mix A and B I'm good.

Then I reinstalled the fuse box.

  Jun 17, 2022     Connected relay wires - (2 hours)       Category: Avionics

Still working on the bundle that comes through the firewall. Secured three wires to the B ground on the fuse box.

Connected the starter relay wires along with the starter to master relay wire. Also added the relay wire to the master solenoid.

I didn't connect the A Grounds because access is impossible . Tony Kirk at Vans suggests just taking the fuse box off.

I also slid a modified grommet per the instructions but will wait to ProSeal the gaps until all the wires are connected.

  Jun 16, 2022     Connected G3x wires to fuse box - (1 hour)       Category: Avionics

Online research revealed the pink heat shrink can come off the connectors. Apparently it's there in the event people fully connected the battery. I have no idea why anyone would connect a battery before the avionics wiring was run but there you go.

I also spent too much time looking for wire K6284. You get spoiled thinking all the wires you need are in the main harness but it's actually a wire found in the AV6000 bag. I couldn't tell what terminal those wires connect to (other than the one ground wire that's attached under the brake reservoir hardware) so it's back to more online research.
And finally, while looking at the routing of K7125 --- the starter relay wire -- I discovered I did not run WH-P154 from the starter relay to the master solenoid. So that's now added to the list.

  Jun 15, 2022     Rerouting wires - (3 hours)       Category: Avionics

I've now figured out that most of the wires have to go up to the subpanel so I rerouted everything.

I have COVID, so the hangar seemed like a good place to isolate today as I worked on 42MiS/U-13. I connected the two orange wires with sockets to the CPU fans with pins and put heatshrink over them but I hate that. Heatshrink makes a lousy connector and they fell apart. I stripped over the heatshrink and added a small piece and then put a second piece over it.

I installed the grommet around the forward cutout but the instructions made no sense to me. They specifically said the forward hole ONLY for us folks with older models. Why? We'll see.

I connected the 25-pin d-sub and the 8-pin molex connectors labeled "HIC" to the AV-60009 ; connected the HIC connectors on the Rotax Fusebox cables to the appropriate receptacles on the AV-60009; cut off the plastic flanges of the 912iS MAINT PORT backshell and secured the 912iS MAINT PORT on wire E6023 (WHT) to the top of the F-01202B-1 .

I then modified 3 grommets to be used for firewall penetration.Using a socket and a vise, squeeze one grommet at a time (as called out in Figure 2) until the socket sheared through the grommet

Then I routed the wires through the opening in the F-01201A-1, wasting a lot of time looking for wires for a Dynon installation; I'm installing Garmin.

I started on the G3X connector, which took awhile to find as it appears in no inventory. Looking at the powerplant instructions, I found a notation that it's in the avionics kit and I found it in the plastic bag AV-6000 with a bunch of other things. But I stopped because I need to figure out how to connect them. Does the heat shrink they come with come off? I'll consult with the experts at SteinAir.

  Jun 13, 2022     These instructions aren't very good - (.5 hour)       Category: Avionics

The Van's avionics instructions are not very good. They're vague in too many parts and they don't match the harness as delivered. Today I discovered an example. The instructions suggest you route all the wires in a portion of the harness through the big hole in F-01202B-1 (the subpanel shelf) that are bundled by a blue tie wrap. But following the instructions to lay out the wires to the various components, I discovered that there are a LOT more connectors that need to come up to the shelf. Now I have to figure out which are which. The instructions also refer to the "main harness." But your harness is now three or four different branches. Referring to the "main harness" tells me nothing.

  Jun 12, 2022     Connected coax to transponder antenna - (.2 hour) Category: Avionics

I've been waiting for the opportunity for Carolie to help me tighten the transponder antenna and she was able to do so this date. Then I attached the coax cable.

  Jun 10, 2022     Installed autopilot disconnect - (.5 hour) Category: Avionics

Routed the autopilot disconnect and attached per the instructions. Also installed the ES-00195 Dimmer Potentiometer.

  Jun 07, 2022     Connected trim wires to connector - (.5 hour)       Category: Avionics

I guess I'd already added the pins to the trim wires some time ago (years, maybe?) so I just inserted them into the DSUB connector along with the two wires that were in the 1 and 2 positions already. Then attached the connector to the power module.

I also attached the autopilot disconnect button to the proper spot.

  Jun 05, 2022     Routed fuel pump wires - (1 hour)       Category: Avionics

Van's solved the fuel pump wire mystery. They're still with the engine as there was no step in the instructions to route them into the cabin. The great Tony Kirk answers the mystery.

"Hi Bob,



I agree, we do not do a very good job detailing where the Fuel Pump connectors are located on the main ECU harness. We should add this info the next revision of section 42M.



In Figure 1 on page 46iS-07, the two connectors marked #19 are the fuel pump connectors. They originate from the main ECU harness at the Fuse Box Lane "B" X2 and the Lane "A" X1 connectors, shown in Figure 3, also on 46iS-07, see pic below.



The wires should be routed through the firewall “Modified AN931-6-16” grommet as shown on page 42MiS/U-14 marked-up in red (below). Unfortunately, the fuel pump connectors may need to be passed through the firewall grommet before you pass many of the other wires through the grommet because of their size.



After passing the FP connectors through the firewall they go down behind the Power Module through the large opening in the F-01202B-1, then to the mating connectors in the RV-12iS harness, as per the instructions you quote.



Fuel Pump identification can be found in the Rotax Heavy Maintenance Manual available at https://www.flyrotax.com/p/service/technical-documentation



If you need part numbers for the connectors themselves, that information is detailed on the Wiring Harness Schematic page 11.



Hopefully, this info gets you one step closer to completion."

----------
When attaching the wires, I indicated on the plans which connection goes to which fuel pump.

Also attached the ground wire from the AV6000 power module.

  May 26, 2022     Finished pilot-side wing pin sensor install - (2 hours)       Category: Avionics

The new US-made step drill came in at Ace to I picked that up only to find the 5/16" hole I'd already made for bushings was appropriately sized. Guess you can never have too many step drill bits. Installed the bushings after determining the ring connectors would not fit through the bushing. So cut off the connector, ran th wire, and crimped on a new ring terminal. Then snugged it down.

I also went back to an earlier instruction (42MiS/U-02 Figure 2) to countersink a couple of holes for a connector. Done. We'll see if it's countersunk enough later, I guess.

And I did more separating of the wiring harness and examining of the plans . The instructions say: "Connect the Fuel Pump 1 (Main) and Fuel Pump 2 (Aux) connectors from the main harness to the corresponding connectors from the Rotax ECU harness. See Figure 1."

That's confusing. There's no connector labels on either connector (just number IDs on the wire). And I don't see the connectors on the Rotax ECU harness. Figure 1 isn't particularly helpful.

  May 24, 2022     Mounted AV-6000 - (1 hour)       Category: Avionics

So the four screws in the AV6000 that come in the unit can be safely removed, the unit installed in the bracket, and the screw/washer callout in the instructions inserted in their place. Of course I lost one screw/washer and will have to order more.

There's no real callout for the dimensions in enlarging the holes in the F-01202B-1 to allow the big Garmin connector to fit through when routing the forward wires (other than a 1/2" radius) and my enlarged cutout was too small, so I enlarged it until I could get the connector, and all the other forward wires out.

I did remove the three connected ring terminals and then reconnect them once that connector was topside.

  May 23, 2022     Began plotting the wiring harness install - (.5 hour)       Category: Avionics

Man, that's a lot of stinking wires! I unpacked the harness with an eye on page 13 of Chapter 42, which is installing the AV-6000. There was reference to connecting ring terminals and the 50 pin connector and a reference to an installation drawing I didn't see. The 50 pin connector is already installed and there's no indication what ring connectors the instructions are referring to so I'm guessing -- guessing -- that they were connected by Stein.

Mounting the AV-6000 was problematic because of four installed screws on the AV-6000. I assume these are removed and replaced with the SCREW 0606MPP-BO/ WASHER 90295A380 combination as called out in the instructions. But I want to make sure the installed screws aren't holding the underlying standoff in place. So I paused to do more research.

  May 21, 2022     Completed stick wiring - (1 hour)       Category: Avionics

The answer to the question of getting thin wires into a d-sub connector is the insertion/extraction tool, which I'd bought from Stein years ago but never used.

Ran into another roadblock. The step drill with a hex that I'd bought last week makes undersized 5/16" holes. Gotta find one made in the USA.

  May 20, 2022     Back to work on the stick grip wiring - (1 hour)       Category: Avionics

The two tiny bushings arrived from Van's so I installed both of those on the pilot and passenger side. Slid heat shrink over the wires and shrunk the base where the wires come out of the stick and ziptied them down as instructed. I stripped the wires and added DSUB pins. But I stopped after trying to get them into the connector. The wires are so thin (24g) that if you try to push the wire to get the DSUB into the connector and locked, the wire just folds over. So I have to do some research to see the best way to do this without screwing up the pins and wire.

Meanwhile, I learned from Josh at SteinAir that the reason I couldn't find the AV-6000 is because they already wired it into the harness. So it's in the big bundle of wires.

I put my glasses down at the hangar somewhere and now can't find them. Cleaned the hangar. Nothing. So now I get to buy a new pair of glasses.

  May 18, 2022     Expanded forward access hole - (.2 hour)       Category: Avionics

I used the new right angle drill to drill a 1/8" hole just off the spot on the forward access hole in the F-01202B-1, then used a cutting wheel in the Dremel to complete the cutout.

I continue to be vexxed by the callouts on the instructions. There are several parts that the instructions call AV-6000 but are AV-6007 or AV-60009-1. But the AV-6000 is an IS Power Module Assembly that is NOT in the bag marked AV-6000

  May 17, 2022     Evaluated holes that need to be cut - (.1 hour) Category: Avionics

Another case of the early fuselage buyers getting screwed by the design of the avionics kits. There are two oval holes those kits on the F-01202B-1s, the instrument subpanel shelf where the newer kits have one large one. So the forward hole needs to be enlarged. I measured and marked off where I'll need to drill a radius hole with the step drill.

  May 16, 2022     Enlarged holes - (4 hours)       Category: Avionics

Although I was able to enlarge a couple of holes with tools I had on hand, there was no such luck with the holes for the wing spar pin switch on both sides. After consulting with VAF and the Facebook group, I bought about $100 worth of tools, but the step bit wasn't a hex, so I trudged to Northern Tool to get one of those. Then I successfully drilled the holes in the F-1204B on each side to 5/16 and installed the switch on the right side. The instruction figure for the left side shows bushings in place so I need to find out what number bushing before installing that one as it has a wire from the fuel tank (which I removed).

I riveted in two ES-00301 (zip tie holder) to the F-01223-L-1 and F-01223-R-1 ribs under the baggage floor which was a major pain in the neck to get to. I routed the trim wire and AOA tube WH-P30-1 to the front of the plane (the AOA tube exited out the side of the fuse, and loosely zip tied the trim wires to the n F-12103-1.

  May 15, 2022     The curse of the early fuselage kit - (2 hours)       Category: Avionics

When Van's introduced the RV-12iS, I was one of the first to get a fuselage kit as I already had an order in for the RV-12 fuse kit when the announcement came. Van's had not yet provided an RV-12iS avionics kit. When it developed that kit, owners of early fuselage parts were now faced with enlarging certain holes for snap bushings and the like. The problem, obviously, wiring runs occur in hidden and small spaces that are impossible to get to by the you reach Section 42. So much stuff is already installed.

That hit me in this work section. The instructions call for holes to be enlarged "if required" which is Van's speak for "if you have an early version of the fuselage kit.

The first called for a 3/8" hole to be drilled in the left and right F-0124F-X-1. No way that could happen with the fuel tank in the way so I had to unhook everything and pull that out (again: good thing the tail cone isn't attached).

But then the next problem hit. You can't really get a straight-in shot at that hole because the side skins curve back toward center. I was able to get "sort of" a straight hole on both sides but it wasn't pretty and I'm not happy with that.

The instructions call for a 5/16" hole in F-01204B-R/L-1 and there's no way. You've only got about 4" of room in the slot for both wing spars so even a right angle drill (the one I have) with a chuck for a step drill won't work.

I'm researching ideas on VAF and Facebook and it looks like a hex-step drill and a flexible attachment might work. It sucks to spend maybe $60 to drill two holes but that's probably what I'll have to do. In the meantime the project is paused while I come up with a solution.

The good news is I was able to open up the hole for the bushing in F-01205B-1 without too much interference from the rollbar. And with the fuel tank out of the way, I was able to tighten the ELT antenna nut.

Increasingly, it's looking like I won't get to the canopy this summer.

I also talked to Kevin and Eric at Van's and they're sending me the two missing snap bushings for the hole at the bottom of both control sticks.

  May 13, 2022     Installed ELT.       Category: Avionics

I have not received an answer to the location of this mystery bushing Van's' instructions call for in the base of the yoke (it also does not appear anywhere in the RV-12 parts list) so I continued on with the ELT installation. I attached the base and straps to the subfloor in the baggage area and secured, routed the connection from the transmitter housing to the audio alert thing and then tie wrapped that down (Van's supplied tie wraps for this are too short so I joined two together. Then I installed the antenna and tightened it down. I'd like to tighten it more but access here is near impossible because of the fuel tank. I attached the antenna cable and routed it to the ELT. I made a split in a bushing to fit the antenna wire through and secured it to the baggage floor. The next step called for a bushing to be installed in the hole forward of the antenna but the bushing callout will NOT fit that hole.

I went back in the instructions, figuring I must've missed a callout to enlarge that hole but I did not. Perhaps the instructions have been updated. I sent a note to Van's. I hope I don't have to enlarge the hole because the drill will be blocked by the angle of the rollbar.

The expiration date on the ELT battery is September 2026.

  May 12, 2022     Canopy lock sensor - (2 hours)       Category: Avionics

The next step in the instructions called for mounting the ELT bracket which I couldn't do because it's back home in the guest room. And after that it's ELT antenna work, which is back home in the guest room. So I moved on to the canopy sensor lock, cutting off the little roller at indicated , attached the space portion of F6035 to the com port and to the rollbar brace as directed, and then mounted the switch to its assigned spot. Not sure I'll be able to go much further on that particular component because I don't have the canopy done. But I had to stop in order to drive three Major League baseballs from Target Field to Apple Valley for three kids I'd promised balls to.

  May 11, 2022     Installed stick grips - (3 hours)       Category: Avionics

It must be an age thing where I miss important details in a simple instruction. I drilled the hole in the base of both sticks. Fine. I drilled the hole in the control head and spacer and stick grip. Fine. I put the foam over the stick (which didn't want to go on). But... fine. I riveted the spacer to the stick. Not fine. I strung the wires down through the stick to exit at the hole at the base. Fine. Except. Not fine. I was supposed to rivet the control head to the spacer to the stick after running the wires. So I drilled out both rivets and restrung the wires, then riveted all three in place (I actually did this part about 11 a.m. after stopping at the hangar after a rained-out Twins game where I'm an usher). Horror ensued as I started to rivet the pilot side when I realized I'd put the foam grip on upside down and surely I did that to the co-pilot side too. But it was... you know... fine. Then completed the process and cut the wires to length down below. And I put the labels on.

However I couldn't put bushings in the lower hole (which I have to do before putting the DSub connector on because the part number listed on the plans does not appear anywhere on the avionics inventory list , so I sent a note to Van's.

  May 10, 2022     Drilled hole in stick - (.5 hour)       Category: Avionics

I was out at the hangar to pick up a lawn mower and thought I'd at least do something on the plane so I drilled the number 11 holes at the bottom of both sticks it's called out in the instructions. I started with a number 40 and then a 30 and a 22 and an 18 then a 14 and a 12 and then at 11.

  May 09, 2022     Com and transponder antenna installed - (1.5 hours)       Category: Avionics

Installed the com antenna which was a tight squeeze for access to tighten the nuts down on AV-00008. Then fit the transponder rod-type antenna, duct taped it in place so I could put the lock washer and nut on. I hand tightened it but I'll need another pair of hands to tighten it down completely.

  May 09, 2022     CPU fans installed - (1.5 hours)       Category: Avionics

I mostly finished the avionics inventory with the exception of the big items which are still in boxes in the guest room. They're going to stay there to be covered by homeowners insurance rather than take them to the hangar. I used TOOL-00005 to drill the mounting holes, then cut the wires on the CPU FAN to length and added connectors, using the ground (black) to connect to one of the screws. I'm not sure on the orientation of the crews but the plans list the parts in order which puts the nut on the to. I'll investigate that a bit. I can always change it.

I also made a spreadsheet of the inventory list in Excel so that I can update the storage location and installation status and search the file alphabetically. I spend a ridiculous amount of time searching packing lists during construction.

Oh, one thing I discovered during the inventory is I did not order the $600 powder coated and labelled instrument panel covers. I've contacted Van's to see if I can send the blanks back and spend even more money.

  Jun 01, 2021     Ordered avionics Category: Avionics

I finally got around to ordering the avionics package and in so doing, decided to go whole hog on the options, with a dual screen Garmin system. The only problem now is there's a backlog because of the chip shortage. Van's says it'll be at least four months; I suspect it will be longer. Whatever.