Nov 14, 2020     Install wiring penetration - (1.7 hours)       Category: Firewall Forward

Installed a stainless steel firewall pass through kit (ACS Part# 09-00978). Aligned the flange in close proximity to the battery/contactor/terminal block on the port side, under the spoiler cable pulley. Used a 3/4" step bit for entry hole. Slight misalignment left a sharp lip on entry. Removed the lip with a slightly larger step bit to 'mill' the lip flush with the pass through flange and reduce the opportunity for chafing.
Per instructions, used a coating of Biotherm 100 firestop sealant on the back of the flange to ensure fire/moisture seal.

  Oct 10, 2020     Wiring - (2.3 hours) Category: Firewall Forward

Continued wiring P-leads, grounds, and control for turbo cooling. Cutting wires to final length and crimping Wirefy heat-shrink connectors.

  Sep 26, 2020     Organize FWF wiring - (3 hours) Category: Firewall Forward

Extended two thermocouple wires to RDAC, organized wiring bundles with plastic wire ties.

  Sep 19, 2020     Extend Thermocouple Wires - (2 hours)       Category: Firewall Forward

Extended EGT thermocouple wire for the #2, 3, and 4 cylinder exhaust gas temperature probes. Printed heat shrink labels and placed them before and after the splice. Used Wirefly crimp splices, testing each splice with a gentle pull on each TC wire. Applied heat to shrink the splices. separated TC from signal wires at firewall. and bound TC wires together with plastic ties.

  Aug 23, 2020     Engine wiring - (2.2 hours) Category: Firewall Forward

Cleanup and secure engine wiring.

  Mar 08, 2020     Revamp FW Wiring Runs - (2.3 hours) Category: Firewall Forward

Reworked wiring runs for ground (black), power supply (red), and instrument (blue, white) to the grounding block, terminal block, and RDAC.

  Mar 01, 2020     FW Terminal Strip Mount - (1.5 hours)       Category: Firewall Forward

Aligned nutplate locations to 1/8" thick AL backing plate. Located, drilled, countersunk (with a deburring tool), and riveted nutplates with soft solid rivets. Located backing plate on FW, drilled 1/8" pilot holes, enlarged to 3/16" with step drill. Deburred back end of stainless firewall with the step drill. Mounted the terminal block with #10 screws, aligned to approximate center of through hole and tightened mounting screws to hold the backing plate. Drilled two of the four mounting plate holes for CPP-34 blind rivets. Installed with hand rivet tool.

  Feb 29, 2020     Backing Plate for Terminal Block - (0.6 hour) Category: Firewall Forward

Cut, filed, sanded and smoothed cuts with Scotbrite wheel for backing plate for firewall terminal block.

  Feb 02, 2020     Rivet Glare-shield Mounting Angle - (0.6 hour) Category: Firewall Forward

Placed 8-10 1/8" rivets in the top and sides of the glare shield mounting angle attachment to glare shield.

  Jan 18, 2020     Remove Glare-shield Rivets - (0.6 hour) Category: Firewall Forward

Removed the remaining 5 rivets from the glare shield attachment angle by filing the shank flat, then used an automatic center punch to push the shank into the rivet far enough that a drill bit could take off the factory head.

  Jan 12, 2020     Remove rivets from glare-shield support - (1.50 hours) Category: Firewall Forward

Drilled out all but 5 rivets on the firewall that attach the glare-shield support to firewall. Support needs to be riveted to glare-shield then glare-shield support riveted to firewall. The five rivets had their shanks even or proud of the shop head.

  Jul 29, 2018     XNS-P10: Engine Baffle - (1 hour) Category: Firewall Forward

Riveted and installed nutplates on port baffle pieced to set rear, side, and fore sections.

  Jul 18, 2018     XNB-P14: Prepare Battery Box for Installation - (2.5 hours) Category: Firewall Forward

Cut two 0.080" x 1" x 6" backing plates, laying out three 1/4" mounting holes with nutplates to spread the weight of the battery across the two plates to the firewall. Drilled six matching through holes in the firewall, a bit oversize to allow space for bolt alignment. Holes in the SST firewall were most easily drilled with a step drill. Step drill was also used on the cockpit side to deburr the holes. Test fit mounting plates to firewall to mark and drill locating holes for a pair of flush pulled rivets in each backing plate to secure the backing plate to the firewall. Firewall rivet holes drilled and dimpled. Backing plates riveted to firewall. Test fit battery box. AN4-5A bolts a little longer than required.

  Jul 18, 2018     XNB-P14: Install Battery Box - (1.0 hour) Category: Firewall Forward

Purchased a stamped aluminum battery box for an 680 batter. Prepared 1/8" aluminum plates as backing plates, using 3, 1/4" bolts on either side of box to secure it and the battery to the firewall. Firewall rivet holes drilled, deburred, and dimpled for flush rivets. Countersunk and drilled in backing plates for mounting battery box to firewall. Backing plates riveted to firewall. Test fit battery box. AN4-5A bolts are a little longer than required.