Jun 18, 2021     Drill Subpanel for RCA Jack Inputs - (0.7 hour) Category: Avionics

Layout and drill for RCA male jacks. Stepped up in drill size to get the correct diameter for the insulating plastic washers. Step drill didn't have the correct diameter; the process was to drill, deburr, check fit, step up another size, repeat until a snug fit with the insulating ring on the plastic washer.

  Jun 13, 2021     Drill Video Subpanel for Power Jacks - (0.4 hour) Category: Avionics

Layout and drill the power connectors for the video sub-sub (sub� panel.

  Apr 18, 2021     Panel wire review - (0.5 hour) Category: Avionics

Identified the OAT probe connections and verified probe operation. Moved and gathered several unused parts of wiring harness into a bundle and secured them with plastic ties to the top of the iBox.

  Apr 10, 2021     Panel changes and documentation - (1.5 hours) Category: Avionics

Moved the master switch to the right side. Documented fuse blocks, fuse number in block and the assigned circuit. Tested radio Tx wiring to control stick switch. Recorded assignments to Google worksheet.

  Apr 04, 2021     Wiring Cleanup and Prep - (2.3 hours)       Category: Avionics

Gathered and organized wiring on starboard side of the panel. Gathered bundles together to secure out of the way. Organized to determine additional actions in preparation for installation.

  Apr 03, 2021     Panel Wiring - (1.3 hours)       Category: Avionics

Installed eyelet ends on two short red 12ga, silicon coated wires to carry power to ECB. Will use spade connectors to connect conductors that will penetrate the firewall.
Wrapped the EFIS control wires (20 gauge, 10' long) from the iBox digital inputs (DB-25 solder tail connector) inside expandable PET split plastic wire loom braid. Took a bit of dexterity to pull back the inside edge of the braid while pushing the 10' length inside the braid with one hand. Four conductors to the HAT switch, four conductors to the individual switches, and a common conductor for the HAT and individual switches. The individual switches common will be grounded, while the HAT switches will be pulled up to 12 volts through a 4.7 M ohm resister.

  Nov 01, 2020     iEFIS page collection - (0.4 hour)       Category: Avionics

Screenshots of MGL Explorer pages. Modifications from stock with several built from scratch. Screen 5 has several subpages to act as a series of checklists.

  Aug 20, 2020     Solder pins to control stick leads - (0.8 hour)       Category: Avionics

Stripped, tinned, and trimmed stick leads to approximately 3/16 in. Clamped serial connector pins in vise and soldered leads.

  Aug 18, 2020     Checkout Tosten CS-8 Grip - (0.7 hour)       Category: Avionics

Checked switch and HAT function, created heat shrink labels for wires. Used Tosten's wiring diagram to find leads for eight switches and two common.
Debating with myself whether to use the common for ground, in which case the switch leads would need a pull-up resister to 12 volts presenting a continuous high input to the digital inputs. Then use the common to ground to change state.
Conversely if the common was at 12 volts the digital inputs would be go to a high state with a switch closure. The question to answer is what the microphone switch will require. The HAT switches could be treated differently than the other four. Will look at some bench testing.

  Jul 16, 2020     Video cabling - (0.4 hour) Category: Avionics

Installed DB-9 solder connector inside hood. Verified wiring continuity between pins and wires. Will likely terminate the video input signal to solder-tail bulkhead connectors.

  Jul 12, 2020     Wiring for cameras - (0.7 hour) Category: Avionics

Began soldering shielded wires to a DB-9 connector that plugs into the MGL EFIS display.

  Mar 03, 2020     MGL GPS Mount Layout - (0.3 hour)       Category: Avionics

Layout and drill initial rivet holes for securing MGL SP-12 TABS to underside of instrument panel with piano hinges to hold the mounting plate to the underside of the instrument panel.

  Feb 01, 2020     Rewire Avionics Power, OAT - (3.5 hours)       Category: Avionics

Changed the wiring from the ECB to avionics fuse box. In the original configuration, the ECB was used to switch the power conditioner supplying power to the avionics fuses. In the most recent configuration, the ribbon cable connector for ECBs 1 through 4 were soldered to their respective grounds. Power from the conditioner was then switched to the avionics fuse box. The poor photograph and incomplete description in the MGL documents required bridging each of the ribbon connectors to determine which pins to solder together.
Attached outside air temperature sensor connections and tested in EFIS.

  Dec 10, 2019     Update MGL Firmware - (0.65 hour) Category: Avionics

Updated G3 Explorer iEFIS firmware to FlightOps system G3 iEFIS 1.0.0.3. iEFIS application G3 A 1.1.0.1 (22 October 2019).

When updating the V16 VHF radio firmware using the Explorer/SD card method, the update routine in the iEFIS asked to cycle the power to the radio. Since the radio power from the ECB is switched in software from the Explorer, cycling the power while leaving the Explorer running was not possible so power was removed from the Explorer. The V16 radio & Razor head power was wired to a physical switch and the update attempted.
After the update routine called to cycle power to the radio, the Razor head indicated no Com radio available, and the Explorer update routine stopping at 1% with a no ack error. Returned the V16 and Razor to MGL for service.

Did not update iBox firmware.

  Nov 30, 2019     Wiring VHF Com Radio - (2.5 hours) Category: Avionics

Opened pass-through in sub-panel support to accommodate a 3/4" dia snap bushing. Organized power and ground instrument panel wires loosely with plastic ties and anchors. Cut, marked, and crimped Faston connectors for power and ground.

  Aug 11, 2019     Building screens for MGL Explorer - (4.5 hours)       Category: Avionics

Used the MGL Simulator to start several new engine monitoring screens. Setup includes monitoring the current flow through each ECB circuit. Tests using the radio circuit was not entirely successful in displaying the current flow through the intended ECB. The circuits were programmed from 1 to 4, the indication is that the first four circuits are numbered from 0 to 3.

  Aug 04, 2019     Add ECB CAN bus - (1.6 hours) Category: Avionics

Built cable to add the ECB to the EFIS/iBox CAN bus. Took several tries setting the ECB DIP switches to set profile 31, permitting circuit breaker programming through the MGL EFIS. EFIS/iBox/ECB. Testing of power input from Power Conditioner appeared to blow 5 amp fuses ahead of the iBox. Tested MGL wiring harness for shorts but nothing evident. ECB
When the EFIS is powered through an ECB, switching off the EFIS then requires cycling main power to ECB to re-enable EFIS (circuit programmed to ON during power up.
The current display through the ECB circuits is done in the Simulator selecting ECB tab and providing an ECB circuit number.

  Aug 03, 2019     Working with ECB - (3.6 hours) Category: Avionics

Powered EFIS and iBox through the electronic circuit breaker (ECB). Several dip-switch profiles were tried along with grounding ECB circuits 1 and 2. bridging the ribbon cable outputs did not activate the breaker(s) every time the power was cycled. Build a wiring harness with CAN bus connections and ground with a DB9 and to enable programming the ECB. Was able to program the EBC from the EFIS, setting profile 31, breaker name, trip time, trip current, and startup state.

  May 17, 2019     EFIS wiring - (1.5 hours) Category: Avionics

Set grounding tabs in sub-panel, riveting two back-to-back. Gathered and organized power wiring to/from ECB and breaker panels.

  May 07, 2019     Sort & label wiring harnesses - (1.2 hours) Category: Avionics

1/2" Dymo heat-shrink label for EFIS power harness. Assemble sub-panel to front panel frame.

  Apr 19, 2019     System Test Failure - (1.4 hours)       Category: Avionics

Reinstalled the MGL iEFIS panel, connected LAN and power cables. The setup had been used for several hours earlier in the week to update firmware on iEFIS and iBox. A thick brown, acrid smoke came from the iBox, with the iEFIS showing sensor alarms. Shut the system down immediately, but too late to prevent damage.
On inspection, one of the large diodes on the iBox board was damaged, which in term damaged the circuit board traces and nearby IC. Although I was unclear as to what and why the failure occurred, the iBox was returned to MGL for examination. MGL was unable to repair the unit. The failure mode suggested was that the DB-9 carrying the power was improperly attached to the DB-9 CAN bus port.

  Jan 04, 2019     Screen Design - (1.5 hours) Category: Avionics

MGL Avionics G3 iEFIS Explorer screen refinements. Screen 1 modified engine1 and fuel1 sections. Adds 'opposed' RPM & MAP roundels, measured and virtual fuel bars. Removed ladder bar 'noise'. Screen 5 moved look ahead airspace and added look ahead terrain. Screen 8 engine combined two bar segments for measured and virtual fuel quantities. Will adjust EGT and CHT alert and warning levels.

  Oct 22, 2017     Connect Instrument Air Tubing to Ports - (.3 hour) Category: Avionics

Connected pitot and total energy ports to aluminum air tubing lines. Inspected rear tail-cone section for installation of static port(s) on port and starboard fuselage skins.

  Oct 21, 2017     Install Instrument Air Tubing - (1.3 hours) Category: Avionics

Tubing runs for pitot, total energy, and static lines from probes in stabilators to instruments. Straightened three 10 foot lengths of 3/16" OD aluminum tubing from coil by using the method in this YouTube video. Put tubes inside a length of PVC conduit to prevent bending while feeding tubing through grommets in bulkhead web. Forward through holes in bulkhead web drilled with closer spacing than plans to accommodate prep and riveting of box.
YouTube video: https://www.youtube.com/watch?v=E-wbErheI14

  Apr 06, 2017     Material for Avionics Tray - (0.7 hour) Category: Avionics

Drilled out discarded left ruddervator (scarred interior skin) to recover ribs and skin. Material will be cut and formed to make an avionics frame to hold EFIS screen, iBox, and electronic breakers.

  Dec 18, 2016     Screen Programming - (7 hours) Category: Avionics

Study of MGL iEFIS G3 Explorer Simulator and screen alteration guides. Built a standard six pack arrangement using PhotoShop to create instrument backgrounds from photos. Six pack layout was designed to minimize the crowded stock screens. Engine screen designed to compliment a two screen panel. Rejected second screen for lack of panel real estate].
With addition of MGL electronic circuit breaker (ECB), a screen for push buttons and specific current flows will compliment the six pack and engine. Working on an uncluttered navigation screen, but it will be difficult to beat Foreflight on a mini iPad. Current panel layout 5B has a center console to mimic a Diamond HT36 center consol. Pilot uses left hand stick, right hand power during powered operation and right hand stick left hand spoiler for glider operation.

  Dec 11, 2016     Customize Screen Design - (5 hours) Category: Avionics

Worked through two "Six Pack" flight screen variations for programming practice.

The six-pack screen design is intended to be a simple, clean flight instrument layout. Prepping instrument photos in Photoshop for use as background images.
I didn't care for the standard six-pack screen that comes as part of the MGL default as it gives up its screen real estate to fit a moving map display. I find the default layout performs both flight and navigation poorly, hence the custom design.
The first design attempt did not use constructions rectangles from the Drawing Primitive. Sizing and layout suffered to a point. However with the addition of 200 x 200 pixel backgrounds, the background size drives the layout. Second design effort boxed each instrument into a square, with smaller MAP and RPM in gauges in the box intersections. That really doesn't work out. Maybe a second Explorer screen is in order to support the primary. Each CHT and EGT sensor can be represented as squares that change color depending on caution or warning settings, which might be and idea for an unobtrusive addition.

  Dec 07, 2016     iEFIS mockup - thermocouples - (1 hour) Category: Avionics

Connect thermocouples to RDAC. Fuel capacity, RPM range setup. Tested ILS approach to KCRW 05. Began to design a "glider" screen.

  Dec 06, 2016     iEFIS Mockup Mount - (4 hours) Category: Avionics

Paint and mount MGL Explorer screen, iBox, RDAC, SP-6, and SP-7, GPS antenna to frame. Wired CAN bus and thermocouple inputs (T/C).
Power supply is 110VAC to adjustable 12 VDC ( nominal 13.6v ).
Nota bene: T/C red is negative. Carry/spacing bar on top, magnetic 'tape' for GPS attachment. Took it 'flying' around the block in the seat of my car.

  Dec 05, 2016     Load iEFIS with Terrain Data - (3 hours) Category: Avionics

Download navidata, high resolution terrain, and map data for MGL iEFIS Explorer.

  Dec 05, 2016     Avionics Mockup - (2 hours) Category: Avionics

Cut and fit aluminum scrap for iEFIS mount. Cutout for MGL iEFIS Explorer. Added mounts for iBox & RDAC.

  Nov 30, 2016     Setup EFIS SD Card - (4 hours) Category: Avionics

Setup of MGL iEFIS Explorer, G3 B.
Downloaded and read the MGL iEFIS User's Guide.
1. Installation of the latest firmware.
2. Download GPX file of US and Canada from www.navaid.com
3. Add to database.
4. Download Digital Obstical File (DOF) from FAA. (https://www.faa.gov/air_traffic/flight_info/aeronav/digital_products/dailydof/)
5. Download Airspace Vector Files. (http://www.stratomaster.com/Data/North%20America%20Airspace.exe)
6. Download female voice file from MGL.
7. Download several VFR sectional files from the FAA. (https://www.faa.gov/air_traffic/flight_info/aeronav/digital_products/vfr/)
8. Run MGL Central version 1.9 to import and compact into a database file.
9. Transfer to micro SD card
10. Load firmware, Navaid, Waypoint, DOF, terraindatabase to iEFIS Explorer.
Installation to database consisting of Navaids, Waypoints,