Project: BuckRV-8   -  
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Builder Name:Buck Wyndham   -  
Project:   Vans - RV-8   -   VIEW REPORTS
Total Hours:3907.05
Start/Last Date:Jan 08, 2002 - No Finish Date
Engine:AeroSport Power IO-375-M1S
Propeller:Whirlwind 330-3B/72H-73 3-blade CS
Panel:G3X, G5, GTN650, GTR20, GTX45R, GMA245, GMC507
 
Friendly URL: https://eaabuilderslog.org?s=BuckRV-8

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Mar 15, 2024     RCP stick wire sheathing - (0.1 hour)       Category: Electrical
Installed some protective wire loom ("snake skin") on the wire harness that connects to the RCP stick.


 
Nov 10, 2023     RCP stick wiring - (1.1 hours)       Category: Electrical
Wired the "aircraft half" of the rear cockpit stick quick-disconnect. I used a 7-pin mini-CPC plug with a fitted dust cap that will keep it clean when the stick is not installed in the rear cockpit. I just need to locate some wire sheathing to give it a nice look.


 
Aug 02, 2022     Aft fuselage wiring anti-chafe - (0.5 hour)       Category: Electrical
Cut and installed a few lengths of split-loom tubing on several bundles of wire in the aft fuselage, to prevent them from ever chafing on rivets, or even on the fuselage skin itself.


 
Mar 18, 2022     Engine wiring - (1.6 hours)       Category: Electrical
1. Began securing the wiring and fuse for the "starter on" light.

2. Continued securing the main power lead from the alternator. I made a bend in it where it transitions from the engine clamps to the engine mount clamps. This will give it some slack during engine starts & shutdowns.

3. Added a pair of Adel clamps securing the cabin heat control cable.

4. Planned the routes of most of the remaining wiring forward of the firewall. I will need to install quite a few Adel clamps on the firewall itself, so I decided to hold off riveting the top skin in place just a little bit longer until that's done. (It makes it SO much easier to install stuff through the firewall when the skin is not there...)


 
Mar 17, 2022     Main alternator wiring; Cabin heat cable clamps - (2.6 hours)       Category: Electrical
After working on the top skin today, I decided to tackle some different projects this evening:

1. Continued to secure the cabin heat cable by attaching it to the top of one of the exhaust hanger rods. (We'll see how this works out -- I may have to move some things around.)


Began installing the wiring to/from the main alternator:

2. Installed two high-temperature Adel clamps on the right side of the oil sump. I had to file their holes out to 1/4" to accommodate the case bolts.

3. Drilled a 1/4" hole in the alternator arm for the Perihelion WhackJack diode.

4. Installed the diode.

5. Fabricated a 6-inch 10 AWG jumper lead with a 0.25" Fast-on tab on one end and a 3/16" ring terminal on the other.

6. Installed the jumper between the diode and the B-Lead of the alternator.

7. Installed the control plug and wire for the alternator.

8. Installed the main power cable to the B-Lead also, then routed both it and the control cable through the blue Adel clamps on the engine case.


 
Dec 30, 2021     Starter cable; Cabin heat door improvement - (2.7 hours)       Category: Electrical
1. Cut the unattached end of the starter cable to length, then crimped on a 5/16" ring terminal and added some heat-shrink. (I was pleased to discover that I ended up using all but 4" of the 2 AWG cable I ordered over a decade ago!)

2. Secured the starter cable in two locations on its way to the starter solenoid -- one on the engine mount using two Adel clamps, and one on the firewall just above and inboard of the cabin heat box. I won't connect the cable to the starter solenoid until the day I'm ready to crank the engine for the first time -- that's my safety precaution to prevent any starter- or propeller-related mishaps while the rest of the airplane is being built.

3. After months of looking at the cabin heat box, I decided I didn't like the four tiny tack-welds that attach the control cable tab to the heat valve. So today I drilled a 1/8" hole through the tab and door, and installed a single steel pop-rivet. That will make me feel much better about its reliability!


 
Dec 12, 2021     Electrical passthrough; Starter tab - (0.6 hour)       Category: Electrical
1. Finished the electrical passthrough installation in the firewall.
2. Began trimming off the lower attachment tab of the starter. This will make it easier to install the inlet snorkel.


 
Dec 08, 2021     Starter feed; Warning light feed, Snapjack - (3.7 hours)       Category: Electrical
1. Installed a SnapJack (Zener diode) by putting the diode in a protective plastic tube, crimping a connector spade on one end and a 16AWG wire with a ring terminal on the other. Then I heatshrinked all of it. The ring will attach to the an engine ground (to be determined later), and the spade will connect to the starter stud. The SnapJack diode is a spike suppression device.
2. Put a 2A fuse into am inline holder, then crimped on a ring terminal to one end, paired with a short section of wire with a male spade terminal. This fuse will protect the "Starter On" warning light.
3. Fabricated a 42" length of 2AWG starter cable with a ring terminal one one end. (The other end will be prepared later.)
4. Connected the starter cable and fuse holder to the starter. Slid a rubber boot into place.
5. Drilled out the holes on a -6 Adel clamp to 1/4" diameter, then installed the clamp on the sump under the left cylinders. This clamp will keep the starter cable secure for the first part of its run back to the starter solenoid on the firewall.


 
Aug 30, 2021     Shunt wiring, aux alternator - (0.7 hour)       Category: Electrical
I didn't like the previous shunt wire connecting the aux alternator shunt and its current limiter, so I remade it and installed it.


 
Aug 11, 2021     Firewall passthrough for wiring - (1.1 hours)       Category: Electrical
Drilled 1-1/8" passthrough hole in the firewall for the engine sensor wiring, next to the original hole. This passthrough will be for the EGT, CHT, RPM, MAP, Fuel Pressure, and Oil Pressure wires.


 
Mar 29, 2021     Wiring cleanup; Top skin - (4.1 hours)       Category: Electrical
1. Because I'm getting ready to cleco on the top skin for a few months, I thought this would be a good time to really finalize the wiring installation behind the panel. I spent two hours really going through it, securing wires here and there, taking care of potential rubbing points, and generally securing everything in a permanent way.
2. I also secured and further organized all the current wires in the avionics "hell-hole." (There will be a lot more, once the engine sensors are installed into this compartment.) I got all the ground wires looking pretty good.
3. Removed all the Garmin avionics and put them back in their protective boxes for now. (Had a tough time getting the right cam on the GMC 507 to release, but Zac stopped by and managed to get it done.)
4. Clecoed the top skin into place.
5. Checked the fit of my new F-473 baggage door hinge support. It fits really well.
6. Studied the plans to see how the skin installation and the baggage door assembly are supposed to be done. Because my kit is a non-prepunched kit, I can't use the newer instructions for building the baggage door, and there will be a lot more guesswork and craftsmanship required.


 
Mar 25, 2021     Wing light final check; Map lights; Harness cleanups - (5.3 hours)       Category: Electrical
1. Just for fun, and because I hadn't done it yet, I hooked up BOTH wingtips and turned on all the wing lights at the same time -- nav lights, strobe lights, and landing lights. It was quite a sight!

2. Twisted a pair of wires for the left map light, the last electrical item aft of the firewall that had to be wired. Installing this wire pair was pretty tricky. I ran the wires down to the spar, and worked out a way to run them on the forward face of the spar web to a pre-existing pass-through, then under the fuel selector, up through the gear tower, across the lower z-channel and over to the lighting controller. Most of this job was done by feel, including securing the wires with silicone tape, zip ties, and/or lacing cord. I even installed it through a protective plastic tube where it bends around the edge of the spar. The tube was bonded to the skin with E6000 adhesive.

3. Continuing the theme of "blind work," I spent over 3 hours securing wires into harnesses under the panel -- again mostly without seeing what I was doing. It's a big milestone because now there aren't any wires visible from a normal sitting position in the cockpit.

4. Cleaned up a bunch of other wires on (or near) the two-tiered avionics shelf.


 
Mar 19, 2021     Left landing light; Euro connectors; TNC connectors; pitot/static - (5.2 hours)       Category: Electrical
1. To track down the inoperative landing light, I tried every trick in the book to avoid what I knew was coming, but I finally had to remove the entire landing light assembly from the wing in order to inspect it, which is a real pain. Sure enough, the main power lead had somehow come out of its push-on connector on the circuit board. Let me just say that I HATE these kind of connectors. They are perfectly suitable for certain hobby applications, but using them in a product that's going in an airplane is insane to me. In this case, connectors like these and the green Euro-connectors are the main power connectors to my landing lights, lighting bus controller and wig-wag controller. (Some people have them on their P-Mags). Be careful of anything that simply tightens a screw down on a bare wire end, or grips when you push the wire into a hole. They are not for aerospace vehicles, IMHO! Anyway, I got it fixed in a permanent way, re-wired the entire section from the lamps to the wing wiring harness, and secured everything back in place. Both landing lights work great now, including the selectable wig-wag feature.

2. Researched how to lower the output pressure on my prop governor. Mine is spec'ed to output 400+ PSI, but my future prop requires 330 PSI maximum. The funny part is, even the prop governor manufacturer can't tell me how many turns of the adjustment screw it will take to get the pressure to 330. So I may have to send it to them so they can hook it up to their test stand.

3. Fabricated two coax ends for the GPS antennas by attaching TNC connectors. I'm still waiting on my right-angle TNCs for the other ends to arrive.

4. Installed the pitot and static connector ports on the Garmin G5.

5. Finalized my order for a Whirlwind 330 (3 blade) prop. It's so new, it's not even on their website yet.


 
Mar 17, 2021     Wing lights ops checks; GTN database update - (2.9 hours)       Category: Electrical
1. Fabricated an 8-foot intermediate harness to connect each wing with its respective fuselage connector.
2. Tested both wing nav lights and strobe lights. Everything works.
3. Tested landing lights. The right one works, but the left one does not. Began troubleshooting by hooking the right wing fuselage connector to the left wing. The left landing light still does not work, so the problem is somewhere in the left wing. Looks like I will have to cut into my nice neat wing harness to see if power is getting out to the wingtip.
4. Programmed the landing light wig-wag module for "single switch" operation. This will turn on both lights "steady" upon activating the switch the first time, and will make it easier to diagnose any wiring issues.
5. Loaded my free North America GTN nav database into the unit. Played around with it and the GDU to see how they interact. I doesn't appear they are sharing much nav data yet.
6. Practiced loading flight plans, changing chart types, activating instrument approaches, setting minimums, tuning navaids, sequencing waypoints, and more, on the GDU. This thing is so impressive.


 
Mar 13, 2021     Avionics setup and troubleshooting - (3.6 hours)       Category: Electrical
Today was a great day.

1. With my friend Jim, we powered-up the electrical system for the first time. At first, only the units on the Main bus were getting power. I was able to power up the Essential bus also, using the "E-Bus Battery Direct" switch, and everything powered up fine. Several LRUs did not seem to be connected, namely the transponder and roll servo. After putting in some basic configuration information, the transponder connected.

2. We also successfully tested the Smoke system relay/wiring and the Pitot Heat relay/wiring.

3. After some troubleshooting, we figured out the Schottky diode between the Main and Essential buses was installed backwards. After flipping it around, it worked fine.

4. We tested both sets of pilot jacks by plugging in headsets to each, using the intercom, and successfully receiving transmissions on Com1.

5. I configured Com2 in the Setup menu, and it too received transmissions.

6. Next, we began to track down why the roll servo was not showing up on the CANBUS device list. First, we removed the wing connector and ran 5 jumper wires between the connectors, but this resulted in a short somewhere that popped the autopilot breaker. Next, we opened up both wing connectors and found that the power and ground appeared to be swapped. We got the leads corrected, but the autopilot servo was still not coming up. More investigation is necessary.


 
Mar 12, 2021     Instrument panel - avionics installation - (3.8 hours)       Category: Electrical
1. Installed GDU 465 EFIS and G5 EFIS units.
2. Organized and tied up some more harnesses.
3. Installed G-5 backup battery.
4. Installed GTN 650 GPS/Nav/Com, GMA 507 Autopilot and GMA 245 Audio panel.
5. Connected all remaining harnesses to the avionics.
6. Installed GEA 24 Engine Interface unit.
7. Moved the wings over near the fuselage and connected the autopilot connector from the right wing to the fuselage.
8. Fabricated a set of power leads from my portable 13.8V power supply to the aircraft battery leads, and attached it.
9. Fabricated a set of test leads from the Powerlet socket to a multimeter.
10. Wrote a checklist for the first power-up tests, which I'll accomplish tomorrow.


 
Mar 11, 2021     Wiring, avionics - (3.2 hours)       Category: Electrical
1. Attempted to connect the lighting dimmer connectors (a pair of mini Molexes), but for some reason the pins wouldn't mate without several of them being pushed out the back side of one of the connectors. I tried flaring the female sockets slightly, straightening the male pins, and several other techniques, none of which worked. After getting a little frustrated, I realized that I could simply cut off the entire six-conductor wire (Photo 1) and both Molex connectors, and direct-wire the dimmer wires to the controller. Which is what I did! (Photo 2).
2. Secured the annunciator cannon plug and several other wire harnesses nearby.
3. Fabricated the BNC connectors for the VOR/ILS antenna coax and the Com 2 coax, and connected them.
4. Cut off and re-accomplished a Seal-All wing root connector in order to facilitate a slight wire re-route inside the fuselage.
4. Re-routed and secured several large wire bundles near the avionics shelf.


 
Mar 07, 2021     Wiring, avionics - (2.1 hours)       Category: Electrical
1. Finished re-wring the VOR / ILS antenna coax run through the tail and fuselage, with new connectors on each end (except the very forward end).
2. Added right-angle connector at radio end of the Com 2 coax and connected it to the rack.
3..Installed final black stainless #8 Torx screws with black washers that attach the main instrument panel to the side panels.


 
Mar 05, 2021     Wiring, avionics - (1.8 hours)       Category: Electrical
1. Installed BNC connector on VOR/LOC antenna.
2. Once I had it done, I checked it with a continuity tester, as I always do. I was dismayed to find that there was a short somewhere between the back seat and the VOR cat's-whisker antenna at the top of the vertical stabilizer. I traced the defect to a segment that runs up the between the VS, so I cut out the bad segment and managed to fish through another section of RG-400 coax. I will crimp some new BNC connectors and hope for the best.

[Postscript: As it turned out, I didn't need to replace the coax. Doing a continuity check only works if the coax is not connected to the antenna base. But at least I upgraded the old RG-58 in the tail to RG-400. So not all was in vain.]


 
Mar 04, 2021     Wiring, avionics - (1.7 hours)       Category: Electrical
1. Finished wiring and lacing the avionics lighting bus wires (yellow wires in the photo).
2. Spliced and secured the Com 1 / Com 2 transmitter interconnect wire.
3. Laced and secured the harness connected to the Volt/Ammeter.


 
Mar 03, 2021     Wiring, avionics - (2.1 hours)       Category: Electrical
Finished wiring the entire Garmin G3X/GTN system, except for the lighting bus connections and antenna coaxes. There's quite a bit of harness organizing and wire lacing left to do, but every major avionics connection is now complete. The best part is there are no more wires hanging outside the plane anymore!


 
Mar 02, 2021     Wiring, avionics - (2.5 hours)       Category: Electrical
1. Separated out and organized all power and ground leads from the GMA 245 and GTN 650.
2. Connected all power leads for the GTN 650
3. Finished pinning and assembling both connectors for the GMA 245 audio panel.
4. Laced and positioned the #1 harness and attached the connector to the avionics rack.


 
Mar 01, 2021     Wiring, avionics - (3.6 hours)       Category: Electrical
1. Installed Garmin config module and fan connector inside main GTN 650 connector.
2. Installed all remaining pins in GTN 650 connectors, and installed connectors in backplate. Installed backplate into rack.
3. Began securing wires on left side of avionics rack.
4. Connected TOGA switch wires and landing light switch wires.
5. Wrangled lighting bus wires.
6. Crimped pins on headset/mic jack wires. These appear to be the last Garmin pins on the instrument panel!


 
Feb 28, 2021     Wiring, avionics - (3 hours)       Category: Electrical
1. Finished pinning and assembling several more Garmin connectors.
2. Spent a long time wrangling wires, getting them looking less like spaghetti and more like loose bundles.
3. Installed the main instrument panel! It will be temporarily attached in place until I'm sure it doesn't need to come out again.
4. Connected several cannon plugs and Molex connectors behind the panel.


 
Feb 27, 2021     Wiring, avionics - (1.6 hours) Category: Electrical
[No photos today]

Continued pinning and organizing various wires behind the panel.
 
Feb 26, 2021     Wiring, avionics - (2.9 hours)       Category: Electrical
1. Organized and wrangled numerous wires behind the panel. Reorganized Adel clamps along the aft edge of the avionics LRU rack to improve clearances for the connectors of the GDU display and G5.
2. Pinned numerous power and ground wires for the GTN 650 (which has 7 of each!)
3. Fabricated and pinned several CANBUS nodes.
4. Pinned and assembled the connector for the GMC 507 autopilot control head. [Photo below]


 
Feb 25, 2021     Wiring, avionics - (2.1 hours)       Category: Electrical
1. Pinned and assembled the large connector for the GDU 465 (G3X display unit).
2. Wrangled more wires into harnesses.


 
Feb 24, 2021     Wiring, avionics - (3 hours)       Category: Electrical
1. Added caterpillar edge protectors to the radio rack in preparation for installing the panel.
2. Laid the jungle of CANBUS harnesses into a rough approximation of where they will be hooked up. Used Velcro straps to hold them in place and adjusted everything so it will be easier to pin the ends.
3. Pinned and assembled five connectors, including the remaining GSU 25 connector, the GTR 20 comm radio, the G5 standby EFIS, and others.
4. Added a row of Adel clamps along both the front and rear edges of the avionics LRU rack.


 
Feb 23, 2021     Wiring, avionics - (3.5 hours)       Category: Electrical
1. Wired a CANBUS node for the GAD 29.
2. Pinned one of the GAD 29 connectors and installed the connector.
3. Finished pinning the other GAD 29 connector. It will be installed with the other harnesses once the panel goes in.
4. Pinned one of the connectors for the GSU 25 and installed the connector.
5. Began pinning the other GSU 25 connector. It will be finished once the GDU 465 goes in.
6. Cut the shielded wires from the FCP and RCP headset jacks to their final lengths, and labeled them.
7. Fabricated and pinned all 7 power leads for the GTN 650. [Red wires]. These will be spliced to their respective power feeds after installation.


 
Feb 22, 2021     Wiring, avionics - (3.5 hours)       Category: Electrical
1. Finished connecting all the final wires on the right subpanel, namely the annunciator dimmer wires.
2. Installed my custom avionics rack onto the Z-braces. (The back four screws took over an hour, thanks to the fact hat I didn't take the time to install nutplates underneath the forward Z-brace. Live and learn!)
3, Began wrangling various wires toward their eventual destinations. Installed three Adel clamps along the back of the rack to get some of the wires organized. Installed caterpillar edging along most of the edges of the rack.
4. Adjusted some of the main power leads from the Schottlky diode and the Main Bus fuseblock to make sure the access door opens and closes without interference.
5. Attached the power and ground leads to the LC-50 lighting controller.
6. Installed two three-position tube manifolds to the GSU-25. These will distribute the pilot and static lines to the GSU, the G5, and the avionics test connections.


 
Feb 21, 2021     Cockpit flood lights; Main switch panel installation - (4.2 hours)       Category: Electrical
1. Yesterday, I thought I might place a pair of LED flood light fixtures under the throttle quadrant and the main switch panel, but today I found different locations for them that are just as good -- on the bottom side of the cross-gear z-brace. I did the installation, ran power and ground wires for the right-hand one, and added the wires to an existing harness.

2. Pre-assembled the structural crossbar under the switch panel and zip-tied a protective plastic tube over it, to protect the wire harness nearby.

3. Blind-riveted the front half of the vertical channel cap to the fuselage, to allow for the installation of the main switch panel.

4. Installed the main switch panel, using #8 black stainless screws with nylon washers..


 
Feb 20, 2021     Wiring, switch panel - (2.8 hours)       Category: Electrical
1. Completed attaching and wrangling of all the main switch panel wires. This panel will reman unattached for the time being, until I can get a pair of LED floodlights installed un the bottom side of it.

2. Secured the wires for the two sidewall spotlights inside the vertical spar channel.

3. Planned the installation of the alternate air control knob in the left gear tower.


 
Feb 19, 2021     Cockpit spotlights; Main switch panel connections - (3.6 hours)       Category: Electrical
1. Installed the two adjustable spotlights on the sidewalls, forward of the vertical channels. They will point downward at the throttle quadrant, the fuel selector, the main switch panel, and the circuit breaker panel.

2. Bolted the side panels to the fuselage longerons. [No photo.]

3. Assembled the main switch panel components. Began connecting and wrangling the wires.


 
Feb 18, 2021     Instrument panel and switch panel - (3.2 hours)       Category: Electrical
1. Finished riveting the right side panel to the mounting angle.
2. Nearly finished connecting all the wires to the right subpanel switches. Only the annunciator dimmer remains to be connected.
3. Wrangled, verified, labeled, and trimmed all 19 wires that will connect to the main switch panel.


 
Feb 17, 2021     Instrument panel: Side panel installation & wiring - (4.5 hours)       Category: Electrical
1. Tied up several wire harnesses under the fuel selector panel.
2. Prepped panel mount angle by painting its edge flat black. This will make sure it doesn't show at the top edge of the panel if there is a gap there.
3. Riveted left side instrument panel to the mount angle.
4. Installed both side panels, clecoing the right side panel in place temporarily.
5. Wired and plumbed all switches and controls on left side instrument panel.
6. Began wiring the right side instrument panel switches.


 
Feb 16, 2021     Circuit breaker panel wiring; Main rollover bar - (3.5 hours)       Category: Electrical
1. Completed wiring the circuit breaker panel, tied up the harnesses, and temporarily installed the panel to check wire clearances.
2. Installed the man rollover bar.


 
Feb 15, 2021     Circuit breaker panel wiring - (2.7 hours)       Category: Electrical
Continued wiring the circuit breaker panel:

1. Completed the Essential Bus wiring.
2. Completed the USB port wiring.
3. Completed the US power switch wiring.
4. Attached the four Main Bus feeds.


 
Feb 14, 2021     Circuit breaker panel wiring - (2.4 hours)       Category: Electrical
1. Organized and tied up some of the wires that run under the circuit breaker panel.
2. Spent most of the evening organizing trimming and labeling the circuit breaker wires, in preparation for hooking them up. I separated them into Main Bus and Essential Bus wires, which will make them easier and neater to hook up. (I also had to re-run the autopilot power wire, because I had previously run it to the wrong place in the cockpit.)


 
Feb 13, 2021     Wiring, circuit breaker panel; Cabin heat box - (2.3 hours)       Category: Electrical
1. Continued to prep wires for installation below the circuit breaker panel. Added heat shrink labels and trimmed wire lengths. [No photo]

2. Installed the scat tube connector (the aft side of the cabin heat valve) on the firewall.


 
Feb 12, 2021     Wiring, circuit breaker panel - (3.5 hours)       Category: Electrical
1. Continued organizing an prepping the wires that connect to the circuit breaker panel. Printed out wire identifiers on heat-shrink labels.

2. Wrangled the wires that go underneath the front cockpit stick, on the forward side of the spar. Since I didn't want to tie them to the fuel line down there, I created some standoffs for another set of Adel clamps that will hold the wires separately.

3. Prepped the backside of circuit breaker panel by writing the C/B identifiers on the C/Bs themselves, so I don't misconnect anything.


 
Feb 11, 2021     Main C/B panel harness; Work seat - (3.9 hours)       Category: Electrical
1. Began wrangling the big mess of wires that will be connected to the circuit breaker panel.. I started sorting them out by which column and row they will be connected to.

2. Because it looks like I'm going to spend a fair amount of time working inside the cockpit for the next week or so, I decided to build a seat. I made a paper template, then cut a floor piece out of 1/2" maple plywood, then attached a plywood back with four hinges. I padded the seat support bar with heavy foam, and used a furniture blanket as a seat pad. It's actually pretty comfortable.


 
Feb 10, 2021     Wire cleanup and lacing, fuselage. - (5.2 hours)       Category: Electrical
Spent over 5 hours cleaning up the wiring, accomplishing wire lacing, and adding Adel clamps throughout the fuselage aft of the spar. I got quite a lot done, but there's a lot more cleaning up to do. After bending over the edge of the fuselage all evening, my back is going to need some rest this evening.


 
Feb 09, 2021     Elevator trim servo; Mag leads - (3.5 hours)       Category: Electrical
1. Many years ago, I assembled and installed the elevator trim servo in the left elevator. When I did so, I also installed a 5-pin DIN plug on the short servo cable (See photo #1). It seemed like a good idea at the time, but I have since figured out a better way to do this connection. So today I cut off the old DIN plug in preparation for installing new, lighter, more reliable connectors.

2. Installed the two wires that will go from the magnetos to the mag switches. Used three Adel clamps to secure them just underneath the left side of the baggage floor, away from all other wiring.


 
Feb 08, 2021     Wiring, miscellaneous - (3.7 hours)       Category: Electrical
I thought I was pretty much finished with all the miscellaneous wiring in the fuselage, but I found a few more things to take care of today:

1. Fabricated and ran the small harness for the aux music input from the left desk panel to the audio panel. Added a connector to the jack end.

2. Attached the 9-pin D-sub connector for the CO Guardian unit under the left desk panel.

3. Ran the cable for the fuel flow sensor to the GEA 24, and attached its connector at each end. Secured this cable and the fuel pump cable to a nearby longeron with an Adel clamp.

4. Continued wire-lacing and securing various wire bundles throughout the airplane.


 
Feb 07, 2021     Wiring, miscellaneous - (2.7 hours)       Category: Electrical
1. Added more Adel clamps to the large Z-brace wiring harness behind the panel.
2. Finished wiring the volt/ammeter by spicing the shunt wires to the display connector wires.
3. Ran all remaining avionics power leads from the Primary and Standby power buses. Bundled and laced all the leads.


 
Feb 06, 2021     Wiring, volt/ammeter - (1.2 hours)       Category: Electrical
Finished most of the wiring for the Volt/Ammeter, which turned out to be more a pain that I thought it would be. The harness will be organized and bundled later, after the panel is installed.


 
Feb 06, 2021     Throttle quadrant wiring - (3 hours)       Category: Electrical
1. It's hard to believe, but one photo represents over three hours of work. I got the wiring done for the throttle-mounted PTT and smoke switch and also the backup PTT. All three have connectors so I can someday remove the quadrant to service/change either the throttle cables or the switches themselves.

2. I also worked on the wiring for the LC-50 lighting controller, which has a dimming circuit that was making me mental. I think I have it figured out now. [No photo of either the LC-50, or me going mental...]


 
Feb 04, 2021     Wiring, miscellaneous - (3.2 hours)       Category: Electrical
1. Began fabricating the harnesses that will connect the front cockpit Push-To-Talks (throttle-mounted and backup) to the audio panel. Also created the harness that will connect to the smoke switch on the throttle. All three switches on the throttle quadrant will have connectors, so that the switches can be more easily replaced if needed someday. This will also ease installation and servicing of the three quadrant control cables.

2. Fabricated the 10 AWG line running from the 40A current limiter to the Aux shunt. The only remaining wires to be attached to the relay panel will be the wires to the starter, and to the Main and Standby alternators. These will be accomplished after the engine is hung.


 
Feb 02, 2021     Wiring, firewall forward - (3.3 hours)       Category: Electrical
1. Located and installed both shunts on firewall.
2. Installed Adel clamps on firewall to hold shunt harnesses.
3. Fabricated and installed the 6 AWG wire that goes from the main ANL current limiter to the Main shunt.
4. Fabricated one end of the 6 AWG wire that will run from the Main shunt to the Main alternator.
5. Ran both sets of shunt harnesses through the firewall and the avionics hell-hole.
6. Installed the connector and harness near the instrument panel that will connect to the volt-ammeter.


 
Feb 01, 2021     Wiring, firewall forward - (1.8 hours)       Category: Electrical
1. Crimpled ring terminals and connected all remaining wires on the firewall relay panel, including the main power relay and starter relay activation feeds, the essential bus feed, the Powerlet charging socket leads and ground, and several others.

2. Bundled all the wires into a harness and secured.

3. Changed out some Adel clamps for appropriate sizes.


 
Jan 27, 2021     Wiring, firewall forward - (2 hours)       Category: Electrical
1. Years ago, when I installed my battery box, I realized that the stock location was going to make it challenging to insert and remove the battery. I put the box on its side and angled it so the battery would clear the lip of the fuselage skin and the cowl attachment hinges. Thanks to the law of unintended consequences, I didn't foresee the Skybolt fasteners I would eventually decide to use for the cowl, and how tall they are. Today, I realized the problem. Looks like my lower cowl will probably have to be attached with hinges, and the upper cowl with Skybolts.

2. Secured battery cable and main power feed line, in several locations each, with Adel clamps.

3. Installed terminal boots on several connections.


 
Jan 26, 2021     Battery cable; Firewall planning - (2.1 hours)       Category: Electrical
1. Fabricated main battery cable from 2-AWG Super CCA Fatwire.

2. Planned the installation of both GPS antennas on a pair of custom firewall shelves I'm going to build. Removed pressure transducer manifold after I realized that Van's stock location will not work in my airplane. (The backup alternator and 90-degree oil filter adapter won't leave enough room to place the antenna shelves side by side on the firewall unless I move the manifold.)


 
Jan 15, 2021     Wiring diagrams; Planning; Firewall electrical items - (2.3 hours)       Category: Electrical
1. Made some cleanups and clarifications to my wiring diagrams. Researched exactly how power is to be provided to the GTN 650, and made sure the wires I'm about to run are properly sized and protected. (The GTN 650 has by the most stringent power requirements of any avionics box in my plane, with seven (7) separate power inputs across three connectors.)

2. Planned the wire routing for the magneto leads, which will pass through their own separate hole in the firewall, and will be routed just underneath the forward baggage compartment on the far left side.

3. Laid out some the major electrical components that will be mounted on the front of the firewall, and decided to mount them together on a custom 5"x9" standoff plate, using Z-channel as a support. I don't have enough spare 0.050" aluminum sheet to make it yet. So for now, I'm going to mock it up with poster-board. (The only items that will not be on this plate are the two shunts.). Each of the items will be fastened with nutplates so they can be easily changed out if needed at a future date.


 
Jan 04, 2021     Wiring, miscellaneous - (4.1 hours)       Category: Electrical
1. Installed aft elevator bellcrank. Connected aft elevator push rod to bellcrank.
2. Ran both transponder RS 232 lines through the fuselage up to the area behind the instrument panel.
3. Added Adel clamps to smoke oil line and wire bundles.
4. Laced more wire bundles in belly of fuselage.
5. Prepped Canbus leads for the GEA 24 Engine Interface Module, then ran Canbus wire through fuselage and out the right wing-root, where it will be added to the autopilot connector.


 
Jan 02, 2021     Transponder mount - (1.8 hours)       Category: Electrical
1. Reworked transponder rack mount to give more clearance from baggage floor.
2. Spliced final power and ground leads to harness.
3. Added second D-Sub connector to backplate.
4. Moved ELT buzzer to give more room for transponder harness.
5. Installed anti-chafe rubber tubing on pitot line.


 
Jan 01, 2021     Transponder installation - (4.6 hours)       Category: Electrical
1. Prepped backshells by attaching grounding blocks.
2. Prepped connector plate by attaching mounting screws.
3. Stripped, crimped, and prepared two RS-232 harnesses.
4. Stripped, crimped and prepped one Ethernet harness.
5. Stripped, crimped, and installed USB port.
6. Rearranged static line to accommodate easier attachment of transponder rack.
7. Prepped transponder rack for mounting.
8. Spliced transponder ground leads.
9. Added anti-chafe caterpillar strips near harness routes.

The end of the tunnel is in sight on this remote transponder installation!


 
Dec 30, 2020     GMU 11 and GEA 24 Primary/Secondary power feeds - (0.8 hour)       Category: Electrical
1. Wired the primary and secondary feeds for the magnetometer and engine interface module.
2. Worked on cleaning up the GTN 650 wiring diagram and clarifying how some interconnects need to be done.


 
Dec 22, 2020     Wire lacing; harness wrangling; access hatch - (3.3 hours)       Category: Electrical
1. Did some shop reorganization. Moved instrument panel to metal desk in preparation for building the Garmin interconnect harnesses. (1.2 hours, but not logged)
2. Began wire lacing of certain harnesses that are definitely complete, such as the ones from the Main fuse block.
3. Drilled a few more pass-through holes and added grommets in aft fuselage. Rerouted several wire runs. Finally got the transponder powers and grounds into place.
4. Installed the Skybolt quarter-turn fasteners in the access door in the aft baggage hat shelf.


 
Dec 21, 2020     Wiring harness, panel switches - (1.9 hours)       Category: Electrical
1. Assembled the harness and CPC connector that will attach all the panel-mounted switches to their respective systems, and allow the entire center panel to be easily removed for maintenance access.
2, Changed out Adel clamps on cross-fuselage Z-brace for larger sizes. (The harness there just seems to keep growing!)


 
Dec 20, 2020     Transponder and pitch servo - (2.6 hours) Category: Electrical
1. Ran Ethernet cable from aft-mounted transponder to the area of the central instrument panel.
2. Ran power and ground wires for the pitch servo.
3. Organized wiring log.

[No photo today.]
 
Dec 16, 2020     Txpdr antenna doubler; canopy slider; ELT; pitch servo. - (5.2 hours)       Category: Electrical
1. Installed antenna doubler plate for transponder antenna in belly, with help from my friend Jim. Reinstalled transponder antenna.
2. Attached canopy slider rail, also with Jim's help.
3. Cleaned up magnetometer wiring and began to run its power and ground leads.
4. Cleaned up ELT wiring. Re-accomplished buzzer connectors. Ran ground. Ran ELT control-head cable to right side of instrument panel.
5. Installed pitch servo bracket.
6. Began wiring pitch servo D-sub connector.


 
Dec 13, 2020     Wiring, miscellaneous - (4.2 hours)       Category: Electrical
1. Drilled a few more holes for wiring in the aft fuselage subfloor.
2. Completed connecting all the strobe, nav, and sync lines, including the very difficult tail connections. Begin bundling those wires with the other harnesses.
3. Installed floorboard adjacent to front seat to check wire clearances underneath.
4. Installed wing root connectors for the left and right wing lights.
5. Ran and installed the OAT data line and its connector at the left wing root.
6. Installed fresh air scat tube in right wing. Connected to NACA duct


 
Dec 12, 2020     Wiring, miscellaneous - (2.2 hours)       Category: Electrical
1. Wired all three strobe sync wires. Almost finished wiring all the external lighting circuits. (All that remains are two more power wires that have to run from behind the rear seat to the wing root area.)

2.Continued bundling wire runs into harnesses and fastening them with temporary zip ties. Once I'm sure there's are no more wires to run, I will use cord lacing to finish the job.


 
Dec 11, 2020     Wiring, miscellaneous - (3.8 hours)       Category: Electrical
1. Wired FCP seat heat switch harness in fuselage.
2..Installed FCP seat heat switch in left sub panel.
3. Wired auxiliary music input jack. (All the items on the fuel selector panel now have a quick-disconnect so the panel can be removed for maintenance purposes.)
4. Ran fuselage wires for wing nav lights, strobes, and their grounds.


 
Dec 10, 2020     Wiring, miscellaneous - (4.5 hours)       Category: Electrical
1. Began cleaning up underfloor wires into harnesses. Secured a few harnesses to floor clamps.
2. Connected remaining FCP stick wires to terminal block.
3. Ran autopilot roll servo CWS line to right wing root.
4. Ran FCP seat heat power and grounds.
5. Installed RCP seat heat switch.
6. Installed FCP backup PTT switch.
7. Drilled mounting holes and attached FCP seat heat relay and harness.
8. Cleaned up Main Bus fuseblock wiring.

9. Picked up some interior parts from Jim, my painter. They look great! [Not included in logged time.]


 
Dec 09, 2020     Misc. wiring - (4.2 hours)       Category: Electrical
1. Re-routed control lead for ELT due to wire harness issues.
2. Begin organizing all the wires that will run to the control panel switch harness and the Main Bus fuse block..
3. Installed auxiliary music input port in left sub panel.
4. Installed several grounds and power leads, including those for the audio panel and LC-50 lighting controller.
5. Cleaned up some wire harnesses under the floorboards.
6. Wired part of front USB port circuit,


 
Dec 08, 2020     Landing light switch harness - (0.4 hour)       Category: Electrical
Created a small harness and installed a connector for the two landing light wires in the fuselage.


 
Dec 03, 2020     System wiring and connector to annunciator panel; hole drilling - (4 hours)       Category: Electrical
1. Rounded up all the aircraft system wires that will connect to the annunciator panel. (Had to reroute some of them to make the transition to the harness easier.) Formed them into a harness, then cut all of them to the same length. Stripped them and crimped on CPC connectors to each one. Added backshell and overbraid sheathing, Inserted the pins into the connector. Screwed on backshell and attached strain relief tabs. Used silicone tape on ends of overbraid. The annunciator system is now DONE except for hooking up a wire to the start relay, which will come much later. Close enough to call it done.
2. Drilled a 5/8" access hole on the aft bottom face of the right gear tower to accommodate more wiring, and installed a grommet.
3. Ran the coax for Com 1 and Com 2 to near their final locations behind the instrument panel.


 
Dec 02, 2020     Main panel connectors - (6.2 hours)       Category: Electrical
1. Created a harness to connect most of the center panel switches via single connector (I was going to include the landing light switch in this harness, but its 14 AWG wires would not work in the CPC connector. Routed the harness along the inside bottom of the panel, sheathed it, and attached it with two Adel clamps attached to the bottom flange of the panel.
2. Created a separate harness and connector for the landing light switch.

I've made sure that all the connectors for the panel are distinctly different, or have a different number of contacts, so there will never be a chance to plug in a harness wrong.


 
Dec 01, 2020     Wiring, miscellaneous - (4.1 hours)       Category: Electrical
1. Continued wiring items on the Main and Essential Buses. Revised a couple of wiring runs for simplicity. Began connecting wires to the fuseblock part of the Main Bus.
2. Installed the wing-root connector for the APRS system.
3. Wired the "aircraft side" of the quick-disconnect for the cockpit lighting rheostats.
4. Designed the CPC connection that will allow for a quick-disconnect of all 6 toggle switches on the central instrument panel.


 
Nov 30, 2020     Wiring, miscellaneous - (8.8 hours)       Category: Electrical
1. Installed numerous wire runs for various items such as the audio panel, CO detector, strobe/ nav lights, landing lights, alert audio, and more.
2. Installed the wigwag lighting controller wiring.
3. Drilled several pass-through holes and installed grommets at several locations in the fuselage.
4. Drilled fuselage pass-throughs for all wing wiring.
5. Installed support clamp for smoke oil line under RCP air vent line.


 
Nov 29, 2020     Wiring, miscellaneous - (3.6 hours)       Category: Electrical
1. Rewired EBus relay after minor design change.
2. Wired power leads to avionics fan.
3. Wired power leads to GTR 20 (Com 2).
4. Located and drilled holes on both sides of fuselage for fuel quantity wires.
5. Located and drilled holes at bottom of gear towers for wire bundle passage.
6. Cleaned up and secured several wire bundles.
7. Revised wiring plan for several items on Main Bus MB1.


 
Nov 22, 2020     Misc. Wiring - (2.3 hours)       Category: Electrical
1. Completed fabrication and installation of the main power feed to the Main Bus,
2. Fabricated and installed the low-amp feed lines to the Essential Bus relay, including a rather tricky installation of a surge diode between the Fast-On terminals.


 
Nov 22, 2020     Main Bus feed - (1.6 hours)       Category: Electrical
1. Ran the 6 AWG main feed line for the Main and Essential buses, through the firewall, up through the right gear tower, and onto the Main Bus. Prepared to connect the ring terminal on the bus side.
2. Completed four more wire runs to the alternator controllers and annunciator panel. (No photo)


 
Nov 20, 2020     Wiring, miscellaneous - (2.8 hours)       Category: Electrical
1. Crimped ring terminals onto a 470-ohm resistor, added heat shrink, and installed it between screws 3 and 5 on the alternator controller, in accordance with my revised wiring plan. This resistor prevents the alternator warning light from coming on at the wrong time.
2. Located and installed the Landing Lights wig-wag controller.
3. Ran new wires from the alternator controller to the annunciator panel. (No photo)
4. Drilled new holes for wiring harnesses to pass through the fuselage at the wing root. (No photo)


 
Nov 18, 2020     EBus wiring - (3.2 hours)       Category: Electrical
1. Wired the "big wire" half of the eBus relay, including running the feeds from the Battery Bus to the relay, and from the relay to the EBus.
2. Worked on various wiring diagrams. Made revisions and printed new sheets. (No photo).


 
Nov 08, 2020     Pitot Heat wing root connection; Fuel flow sensor connection. - (2.1 hours)       Category: Electrical
1. Installed final wiring from Pitot Heat relay to aircraft ground. Installed fuselage pass-through. Fabricated Pitot Tube power connection at wing root.
2. Fabricated quick-disconnect for Fuel Flow sensor.


 
Nov 05, 2020     Pitot heat wiring; Pitot tube - (3.3 hours)       Category: Electrical
1. Removed the ground lead from the pitot tube that I had previously installed using the airframe a grounding point. Replaced this with a full-length ground wire that will go to the central grounding block in on the firewall. Secured the ground, power, and OAT wires within the wing along their runs.
2. Installed an Adel clamp to keep the wires away from the aileron pushrod when the wing is installed.
3. Installed overwrap and a two-place Seal-All connector for the pitot heat wires at the wing root.
4. Installed the pilot tube connector onto the wires.
5. Installed the pitot tube. Connected pitot line.


 
Oct 26, 2020     Front and rear headset jack wiring; Schematic revisions - (2.9 hours)       Category: Electrical
1. Did numerous revisions to the schematic diagrams, mostly editorial updates and clarifications.
2. Began running all the cables for the front and rear headset jacks (two 2-wire and two 3-wire shielded cables). Got them near where they will terminate on each end. Next will be attaching the jacks.


 
Oct 23, 2020     Old OAT probe wires; wing wiring connectors; planning. - (3.1 hours)       Category: Electrical
1. Removed the old leads connected to the superseded GRT OAT probe, and secured them inside the wing. I am not removing the probe because there's neither a good way to get to it, nor a good way to plug the hole. I figure it could also someday be a backup OAT probe, if need be.
2. Completed the installation of the lighting connectors on both wing roots.
3. Began planning the comm antenna coax runs inside the fuselage.
4. Continued planning the CANBUS wiring run in the right wing.


 
Oct 21, 2020     EBus relay mounting; wing lights connector - (1.7 hours)       Category: Electrical
1. Removed GEA 24 mounting plate and installed mounting two nutplates to hold the E-Bus relay. Installed relay.
2. Began installing 6-place Seal-All connectors at the left wing root for the lighting circuits.


 
Oct 18, 2020     Misc. electrical wiring - (3.2 hours)       Category: Electrical
1. Applied two coats of rubber insulating coating to the contacts on the backup starter switch, since it will be installed the left gear tower (which is a very busy place, and the consequences of a short across the back of this switch would be bad).
2. Installed and began wiring the pitot heat solenoid.
3. Wired the interconnect wire between the left and right mag switches. (The mags will be wired so that the Left mag must be ON and the Right mag must be OFF in order to start the engine.)
4. Installed the RCP USB charger port in the right rear seat bulkhead.
5. Installed miscellaneous wiring runs,


 
Oct 17, 2020     Pitch trim wiring; backup start switch and wiring - (1.8 hours)       Category: Electrical
1. Wired the pitch trim servo to the Safety Trim controller. Used a pair of D-sub pins/sockets as connectors that can be easily reversed to correct any reverse motion once the system is fully operational.
2. In the backup start circuit, I figured out a way to eliminate about 6 feet of wire, four connectors, and two wire passes through the spar.
3. Located and drilled mounting hole for the backup start switch. Ran wires.


 
Sep 27, 2020     Seat heater wiring; RCP air vent mount - (2.4 hours)       Category: Electrical
1. Made custom wiring harness and connectors to connect RCP seat heat switch to the underfloor relay. Ran harness.
2. Figured out how to mount RCP air vent so that the rear stick cover plate can easily be removed for inspection/maintenance purposes. Fabricated attach ring from 0.040 aluminum.


 
Aug 12, 2020     Flap limit and trim mode microswitches - (2.4 hours)       Category: Electrical
1. Completed installation of the three wire runs that go to the flap limit and trim mode microswitches. These were especially challenging.
2. Began securing the underfloor wire runs.
3. Continued prepping several interior pieces for painting.


 
Jun 27, 2020     Wiring, power distribution - (1.2 hours) Category: Electrical
Did some miscellaneous wiring. (No photos)
 
Jun 25, 2020     Annunciator panel; power/ground wiring - (2.3 hours)       Category: Electrical
1. After more research, I figured out a way to revert back to my old 9-light annunciator design. Instead of the high-brightness, modified 5VDC LEDs I was using before, I'm just going to use the stock 12VDC ones, and accept that they will perhaps be slightly dimmer. They'll still be fine. The unforeseen consequences of using the modified ones were just too much for me to deal with right now.
2. Wired power and ground leads for various components, such as the transponder, Intelligent Power Stabilizer for the EFIS, and others. [No photo.]


 
Jun 12, 2020     Annunciator redesign; misc. wiring - (4.5 hours)       Category: Electrical
1. After much thought and fooling around with diodes, resistors, and breadboards, I decided to scrap my original design for the annunciator panel. When I originally bought the nine 12V LED fixtures that were going to be used in this panel years ago, I rebuilt all 9 fixtures to accommodate high-brightness LEDs, but with this change came lots of extras: dropping resistors, diodes, and lots of modifications to the fixtures themselves. With the recent realization that these fixtures are now expensive and hard to find in case I ever need to replace one, along with the extra complexity that I had inadvertently designed into the annunciator system, I took a step back and re-thought the whole thing. The annunciator panel will now be considerably simpler, and I am going to use the stock 12VDC LED fixtures, which have a dropping resistor built right in. I also removed one light (APRS) in order to accommodate two stock B&C indicator lights for the alternators. I have been assured that the 12VDC LED fixtures will be sufficiently bright. I just hate that I paid $0.89 each for these fixtures at MPJA Electronics in 2014, and now SteinAir is the only place selling them... for $11.40 each. Grrrr.
2. Continued wiring various systems, including the RCP Stick Enable system and the Pitot Heat. Decided to use a small relay for the pitot heat, since it can draw 8.5A at steady-state, with a 15A inrush load.


 
Jun 11, 2020     Annunciator panel - (4.6 hours)       Category: Electrical
1. Fabricated the box structure that will hold the annunciator panel. Bent a box out of 0.025" aluminum, riveted it together, then bonded the back plate to it.
2. Crimped the 330-ohm LED dropping resistors to some butt connectors. These will eventually connect them to the plug leads.
3. Connected all the ground leads of LEDs 4-9, and connected a common ground wire to them.
4. Prepped four additional 470-ohm resistors for use on LEDs 2 and 3.
5. Prepped some Zener diodes that will be connected across the LED leads.
6. Researched voltage regulators.
7. Researched Garmin G3X discrete outputs. Decided to change one annunciator light to a Master Warning.


 
Jun 10, 2020     Smoke system relay and wiring - (2.6 hours)       Category: Electrical
1. Installed smoke pump relay under aft floor. Drilled wire holes in substructure. Ran main power and ground wires for pump.
2. Cut off original Molex connector from the pump and installed a pair of weatherproof Seal-All connectors instead. (I like Seal-Alls because they are very robust and have a long, successful history in the automotive industry. These connectors are probably the ones under the hood of your car.
3. Prepped and painted the front plate for the annunciator panel.
4. Finished drawing the schematic for the new annunciator system, except for the oil pressure warning. I still have to figure out how to get one of the Garmin GAD 27 discreet outputs to turn on an LED.


 
Jun 08, 2020     Wiring, miscellaneous; smoke system relay; annunciator. - (3.2 hours) Category: Electrical
1. Did some more wiring of power and ground feeds.
2. Continued engineering the revised annunciator panel.
3. Drilled location for mounting of smoke system relay. Cut and installed Zener diode on relay. Planned wiring runs, Revised schematic diagram slightly.

(No photos today.)
 
Jun 07, 2020     Annunciator panel; general wiring - (3 hours)       Category: Electrical
1. I came up with a simpler, more elegant way to control the annunciator lights. This allowed my to remove the previous annunciator control box. I also finally designed and fabricated the first stages of the structure that will protect the LED leads and the wires and dropping resistors that will feed the panel. I Mocked it up and temporarily installed it to verify it will work. I think we have a winner.
2. Continued installing power and ground feeds to various systems, including the annunciator panel and the Garmin G5.


 
Jun 03, 2020     Wiring, miscellaneous - (2.2 hours)       Category: Electrical
1. Wired more miscellaneous systems, including the last of the flap and boost pump wiring. (The flap microswitch is one of very few local grounds in the airplane, and installing the ground was a challenge because of the geometry of the switch.)
2. Installed a weatherproof connector in the boost pump line, to facilitate repairs/replacement someday.
3. Got my newly-re-cut panel back, and spent some time deburring the panel and fitting the avionics stack attach angles.


 
May 29, 2020     Wiring, miscellaneous - (1 hour) Category: Electrical
Did miscellaneous wiring on the trim system. (No photo today).
 
May 28, 2020     Wire braiding for shunts; Wire standoffs in hell-hole - (1.2 hours)       Category: Electrical
1. Created two 4-foot long wire braids of 3 x 22AWG wire to match the volt-ammeter manufacturer's factory braids, which are unfortunately too short.
2. Installed 3 Adel clamps on standoffs in the avionics hell-hole -- one for the smoke oil line, and two for a large bundle of ground wires that will be connected to the main grounding block nearby.


 
May 26, 2020     Wiring, trim system - (3 hours)       Category: Electrical
2. Wired most of trim relay deck, flaps-up microswitch, and Trim Mode switch.
2. Began to straighten up the trim wiring and secure it with zip ties for now. Will lace them later.


 
May 25, 2020     Wiring, miscellaneous - (3.4 hours)       Category: Electrical
Did more power and ground runs for numerous systems, including the fuel pump and fuel flow sensor, both of which which required some careful planning and hole-drilling.


 
May 23, 2020     Wiring, miscellaneous - (4.1 hours)       Category: Electrical
1. Installed a terminal block for the starter wiring, since I will have both a stick-mounted starter switch and a backup switch. Began wiring it.
2. Ran multiple power and ground wires, including those for the starter system, mag switches, fuel pump switch, and fuel pump.


 
May 22, 2020     Revisions to E-Bus relay and and Battery Bus - (3.5 hours) Category: Electrical
Spent the evening revising my Essential Bus relay design, and engineering a way to mount it in a different location from where I'd originally put it. This will eliminate an always-hot wire running all the way from the battery to near the panel. After the change, the battery bus and E-Bus relay will be in the forward avionics bay, just inside the hole where the hot lead comes through the firewall. I would have preferred to put both these items on the forward side of the firewall, but I was concerned about their ability to withstand the heat. I haven't sacrificed too much safety by putting it in the bay. Everything's a compromise with an RV-8, due to lack of space.

No photo today.
 
May 21, 2020     Wiring, power distribution - (4.2 hours)       Category: Electrical
Ran power feeds and grounds for 7 components and switches, including the battery solenoid, Start Arm switch, DC Master switch, Standby Alternator Arm switch, and the remainder of the Essential Bus feeds.


 
May 20, 2020     Main and essential buses; Lighting controller - (4.1 hours)       Category: Electrical
1. Wired main power leads to Main and Essential buses.
2. Wired power lead for Main Alternator Controller.
3. Ran all "bank feeds" between Main Bus distribution bar and circuit breakers.
4. Began wiring LC-50 Lighting Controller by attaching cable clamp for the 6-conductor dimmer cable, and attaching all six leads.
5. Began fabricating the lead from the Essential bus to the E-Bus relay. The relay uses large 0.375" spade receptacles, and I need to order some. (No photo)


 
May 19, 2020     Wiring alternator controllers & Hall effect current sensor - (1.5 hours)       Category: Electrical
1. Almost finished wiring the alternator controllers. I had to remove four of my previous wire runs because the manufacturer up-sized the recommended wire gauges in the past few years.
2. Wired the Hall effect current sensor, and secured the sensor itself on the firewall, for later installation.


 
May 12, 2020     Wiring alternator controllers - (1.8 hours)       Category: Electrical
1. Wired the LR-3 Main Alternator controller.
2. Began wiring the SB-1 Standby Alternator controller.
3. Ran all wires to their approximate final locations.


 
May 11, 2020     Flap wiring; aileron trim servo - (1.5 hours)       Category: Electrical
1. Wired the flap motor. (I had to use a little LPS-2 to help ease the wire pair through the plastic flex tube, but other than that, it went great.) I designed this tube installation to protect the wires from chafing and pinching as the flap motor moves up and down. The diode on the terminal block is a bi-directional zener diode that will help protect the flap motor from reverse voltage transients.
2. Installed the aileron trim servo.


 
May 08, 2020     Trim system - (1.4 hours)       Category: Electrical
1. Wired a Mini-Dean's connector to the aileron trim servo leads.
2. Began installing the trim system harness.

We're getting into the "wiring spaghetti" phase!


 
May 05, 2020     Wiring planning; wiring - (5 hours)       Category: Electrical
1. Worked on updating wiring diagrams with all wire gauges so I can speed up the wiring process. (No photo).
2. Wiring a couple of small items, including the flap switch and the spike-catcher diode for the flap motor terminal block.


 
Apr 30, 2020     ELT wiring; USB charger wiring - (1.7 hours)       Category: Electrical
1. Drilled a couple more bulkhead holes and installed snap-grommets.
2. Installed ELT and ran its cable up to the cockpit area. (The actual ELT box will be removed soon, so I don't inadvertently set it off.)
3. Ran the power.ground wires for the rear-seat USB charger and for the switch that will control both outlets.


 
Apr 29, 2020     Wiring; ELT harness - (4.6 hours)       Category: Electrical
1. Located and drilled holes in various bulkheads. Installed snap-bushings. Ran wires in fuselage for the aft USB port and the rear cockpit headset jacks. (No photo).
2. Figured out a location for the ELT buzzer, and match-drilled mounting holes in the bulkhead near the ELT. (No photo).
3. Increased the puny 26-AWG leads on the ELT buzzer to 22 AWG so I could use crimp connectors, by soldering on some short 22 AWG wire. Planned for future replacement by installing spade disconnects in the buzzer leads.
4. Wired the DB-15 connector for the wire harness. Figured out how to create a common ground for the buzzer, the ELT unit itself, and the serial line from the GPS.
5. Installed the buzzer using #4 hardware.


 
Apr 22, 2020     Trim system - (2.3 hours)       Category: Electrical
1. Took delivery of my newly black powder-coated control sticks. Installed them to get a rough idea of how much length will have to be trimmed from the tubes, as well as the lengths of the wire runs that will be needed from the sticks to the terminal blocks..

2. Installed the two terminal blocks for the stick wiring. (The front cockpit will actually get one more small one, used for the starter-button wiring.)

3. Drilled and installed the Safety Trim box, underneath the rear seat.

4. Drilled and installed a few wire passthrough snap-bushings.

5. Installed a few Adel clamps that will support the trim wiring as it exits the control sticks and makes its way to the SafetyTrim box. The wiring will have to pass underneath both the right aileron pushrod and the elevator pushrod, so I had to plan carefully.


 
Apr 21, 2020     Stick grips and trim module - (3.5 hours)       Category: Electrical
1. Scouted a suitable location for the Safety Trim module (which is my relay deck for the trim system), and the terminal strips I will be using to hook them together.

2. Researched the Garmin requirements for the Push-to-Talk buttons, Com frequency swap, and Control Wheel Steering (CWS) for the autopilot. Researched the current limitations of the stick switches just to make sure I don't need another relay for the Engine Solenoid (I don't), and researched the wiring details of the Infinity Aerospace sticks.

3. Drew out a plan for all the connections under the floorboards, and began making a plan for how to run all the wires.

4. Removed much of the outer sheath from one of the stick grip's wire bundles, by hand. (It's a slow process, but it's not as painful as I thought it would be. I probably could have used a knife, but I didn't want to risk nicking a wire.)


 
Mar 24, 2020     Avionics access door, Main Bus, and diode - (1.2 hours)       Category: Electrical
Labeled Main Bus fuse block. Attached it and the Schottky isolation diode on the back of the avionics access door.


 
Jan 30, 2020     Bus distribution bar plate - (0.6 hour)       Category: Electrical
Mounted the Main and Essential distribution buses to their mounting plate, then mounted the plate back on the bulkhead behind the instrument panel.


 
Jan 27, 2020     Bus distribution bar plate - (2.2 hours)       Category: Electrical
Modified old Approach Stack Hub mounting plate to accept the Main and Essential Bus distribution bars. Drilled mounting holes, "Dremeled-off" the existing locating pins, filed and polished all edges, sanded all surfaces, primed, and painted.


 
Jan 25, 2020     Electrical bus distribution buses - (1.0 hour)       Category: Electrical
Worked on various designs for how to mount the two distro bars. Since my Approach Stack avionics hub in now obsolete (at least for the avionics I'll be using), I think I might be able to reuse the hub's mounting plate for this purpose. The distro bars fit perfectly, and the nutplates for the mounting plate are already installed on the bulkhead between the cockpit and the forward baggage compartment.


 
Jan 14, 2020     Essential Bus and Schottky Diode - (1.9 hours)       Category: Electrical
Beginning to re-work the Main Bus, Essential Bus, and the large diode that connects them (Photo 1). Since the Essential Bus will now have circuit breakers instead of an ATC fuse block, I began to try out different mounting locations for the Main Bus, diode, and E-Bus Distribution Bar (Photo 2). As I removed the diode (Photo 3), I inadvertently spun one of the mounting studs, and it looks like it will be too much of a pain to fix it. So I'm ordering a different one, with a different style of package. This all means that most of the holes in the avionics access door will be unused, and it will look ugly. So now I'm thinking about making a new door.


 
Jan 07, 2020     Aft fuselage wiring revisions - (1.4 hours) Category: Electrical
Removed 6-conductor phone cable from old ELT remote installation. Began re-routing transponder antenna coax cable from instrument panel area to left sidewall, aft of baggage compartment, where the new remote transponder will go.
 
Mar 28, 2019     RCP USB Port Upgrade - (.5 hour)       Category: Electrical
Today, I managed to finish painting the mounting plate for the rear cockpit USB port, and install the port. One more little project done.


 
Mar 19, 2019     RCP USB Port Upgrade - (1.2 hours)       Category: Electrical
Today I finished making a cover/attach plate for the Rear Cockpit USB charger unit. Then I trimmed out the rectangular hole needed in the bulkhead, drilled new attachment-screw holes, and test-fit the unit, I sanded and primed the plate, and now I have to decide what color to paint it. I'm thinking dark gray. The attachment screws are black allen-head cap screws to match the military theme of the cockpit.


 
Mar 13, 2019     RCP USB Port Upgrade - (.5 hour)       Category: Electrical
Getting back to work on the RV! In the last 4-5 years, USB charging has become THE mainstream way to charge devices, so I decided tro pull out the old Powerlet sockets that I'd installed, and install new USB charging ports. The first one to be replaced is the one on the right side of the rear cockpit. Today, I laid out a new attachment plate on some 0.40 aluminum sheet.

The charger I'm using in this location is made by Radiant Instruments (Belite Aircraft), and it's supposed to be tested and suitable for aircraft use, with no interference or EMI.


 
Jan 31, 2015     Dummy panel fit; Side switch panel; Flap control - (3.3 hours)       Category: Electrical
Today, I made some really rewarding steps forward:

1. I installed the foam-core test panel in order to verify the placement of my avionics, clearance from the attachment flanges and other installed items, planned wiring runs, and general ergonomics issues. I noted that there are three nutplates at the top of the panel that will have to be turned 90 degrees and replaced with stubby versions in order for the GRT EFIS screens and the Monroy Traffic Watch unit to be installed in their planned locations. I will also have to cut away a small amount of flange in a couple of other locations. None of these is a big deal, and it's great to know about the issues now instead of later. My next step is to install the actual avionics boxes, one at a time, to verify clearances from the bulkhead and support structure behind the panel. I don't foresee any big issues.

2. I also clecoed-in the side switch panel, with the switch template taped to it. I had to verify that the switches will be easy to reach, and the labeling will be easy to read from a normal sitting position. Everything looks good.

3. A while back, I located a neat switch plate and lever for my flap switch, and today I assembled it to verify the ergonomics issues. I like it better than the layout I had previously designed.


 
Jan 30, 2015     Throttle PTT; Pitot heat connector - (2.1 hours)       Category: Electrical
I disassembled the existing grip on my throttle grip, and began changing out the stock wiring with something a little more lightweight. The stock "Fatboy" rifle grip contained a massive, 7-conductor coiled cable which, while it would certainly serve its purpose, it a bit of overkill for my installation. I will replace this cable with two 22 AWG wires, one of which will be grounded someplace near the throttle quadrant.

A while back, the connector that attaches to the bottom of the heated pitot tube crumbled without any provocation, and I bought a new one. Today, I prepped the connector for installation in the left wing as soon as it comes off the airplane. By the way, these connectors must be, pound-for-pound, one of the most expensive parts of an airplane. This 1-1/2" piece of phenolic/plastic costs $170 plus shipping, and they are backordered for three months. Yikes. Don't break yours.


 
Jan 22, 2015     Flap/trim mode microswitches - (3.0 hours)       Category: Electrical
Continued installing my custom flap and trim mode microswitches, and the actuating arm for them. It was a bit tricky to get it done with only two hands, but I finally got what I think is a very robust installation. Some tips for anyone doing this style of installation:

1. Use star washers between the aluminum angle and the Adel clamp (on both sides). This will help prevent any movement of the clamp. It basically makes the clamp and the actuating angle into one stiff piece.

2. Use a #13 Adel clamp on the flap arm, not the #14 I initially used.

3. Don't worry too much about getting the angle to hit both switches exactly at the same time. The flap motor actuation point is the critical one in my application. The actuation point of the trim system switch is not critical. Besides, if one of the switches actuates at the wrong time, you can always file a bit of the angle away on the side that is actuating "early."

4. Label the switches NOW, so you don't forget which one is which 10 years from now, when you're trying to service the system.


 
Jan 20, 2015     Flap microswitches - (3.3 hours)       Category: Electrical
Purchased and modified two new microswitches that will be better capable of handling the load of the flap motor. (Only one of the switches needed to be this robust, but I wanted both of them to be identical in form factor, so the trim mode switch will be a bit of overkill.) Luckily, the new switches utilize the existing mounting holes after the holes in the attach angle were opened up from #4 to #6. The "modification" of the switches involved trading out their stock springs with... wait for it... springs I cut from a Bic pen in my kitchen drawer. I didn't like the weak stock springs, and after looking all over town for a suitable replacement, I realized I had some suitable ones right under my nose. I cut the pen spring in half, and the halves were perfect. I mounted the switches to the attach-angle with #6 stainless hardware.


 
Dec 23, 2014     L wingtip nav lens and nav light - (1.2 hours)       Category: Electrical
With just a couple of hours available this evening, I had to be selective. It was just enough time to finish up the left nav light enclosure. I cleaned and scuffed the back sides of the reflectors, applied some Goop adhesive, then screwed them into position (with three SS screws on one side, and with the nav light iteslf on the other). Then I installed the connector shell to the terminals. Finally, I masked and painted the outside edges of the lens with a strip of black paint. I'll post pictures of that once it dries. The left wingtip is essentially done.

I also moved over to the fuselage and spent some time documenting the issue I'm having with the clearances on the flap rods. I will be sending some photos to Vans this evening. Maybe they can figure out what the problem is.


 
Dec 16, 2014     L wingtip wiring - (3.1 hours)       Category: Electrical
Spent some time on the left wing wiring:

1. Cleaned up the wiring harness on the L wing rib, including re-routing everything up a few inches to keep the power wires slightly further away from the Marker Beacon antenna.

2. Improved the airframe ground for the landing light.

3. Added an Adel clamp to provide more strain relief for the ground above.

4. Installed a 4-conductor Seal-All connector to the end of the nav/strobe light cables.

5. Installed a BNC connector on the end of the Marker Beacon antenna coax.

6. Installed a mating Seal-All connector and some sheathing on the nav light itself.


 
Dec 13, 2014     R wingtip lights, APRS and electrical - (2.5 hours)       Category: Electrical
I did a lot of little cleanup items tonight:

1. After a successful test of the APRS unit in my car this afternoon, I pronounced it to ready to install in the right wingtip. I torque-sealed all the barrell nuts, screws, the SMA antenna connector, and the DIN connector. With the exception of using double-sided tape to attach the GPS puck to its wooden base, the APRS system is now complete.

2. Did some further organization of the wiring on the right wing rib, and figured out where the nav/strobe lights connector would go. As it turns out, the best way for me to do this was to have the connector be located just 8" from the nav light fixture itself. This eliminates any extra spliced-in lengths of wire.

3. Installed 4-conductor Seal-All connectors on both ends of the nav/strobe leads. The Seal-Alls are commonly used in high vibration, extreme conditions in automobiles, trucks, boats, etc., and they are very reliable. The housing for the wingtip end of the connector will be installed after the nav light wires are fed through the wingtip mounting holes for the last time.

4. Bundled the 4 nav light wires and created a nice little wring harness coming out of the nav light.


 
Dec 11, 2014     R wingtip wiring - (1.0 hour)       Category: Electrical
I'm still fiddling around with various wingtip connectors for the APRS transmitter in the right wingtip. I decided to install a set of polarized Anderson PowerPole connectors. They should work fine, after I secure the two halves of the connector together with a a small zip-tie.

I also cleaned up the wiring on the end of the tip rib, moving the higher-current power feed for the nav/strobe lights up and away from where the APRS J-pole antenna will run. Several tie-wrap bases were replaced with better ones, and all wires got protected with silicone tape where they are tie-wrapped.


 
Nov 19, 2014     Systems revisions and slight redesigns Category: Electrical
(22.5 hours) I spend a lot of time of the past week reviewing my electrical system, cable runs, connectors and other critical parts of the wiring puzzle. It's been interesting and challenging to get back into the proper mindset. Several key changes were made, including some of the functions on the stick buttons, the substitution of several avionics boxes that are no longer available with ones that are, updating labeling ideas, renumbering all components, updating schematic diagrams, checking ergonomic issues, revising the annunciator panel design, etc.

I also made contact with the folks at Avidyne to confirm that the IFD440 Nav/Com/GPS is truly going to be released soon, because I am now committing to it. I hope they can deliver! [Superseded.]

Finally, I bought a Garmiin SL30 (my Com 2) from a gentleman in Kentucky who is upgrading his panel.
 
Sep 17, 2014     Removed tail camera wiring - (1.1 hours)       Category: Electrical
Removed tail camera wiring run from top of VS to rear baggage compartment.


 
May 09, 2011     R wing wiring connector - (1.1 hours)       Category: Electrical
installed one half of the power connector for the APRS unit that will be installed in the right wingtip. I've elected to use SealAll brand connectors, which are basically higher-quality, weatherproof versions of the ubiquitous Molex connectors that are traditionally used in homebuilts. These are the same connectors used by GM in many modern cars, so I figure they've been pretty well ops-tested and proven reliable. They feature a locking tab that keeps the connector halves together no matter what, plus rubber grommets on the back end of each wire, and another grommet on each mating fitting.


 
Jan 08, 2011     APRS wiring - (.9 hour) Category: Electrical
I decided that I will place the APRS transmitter in the right wingtip. Since the APRS antenna will also be in the wingtip, I can now remove the previously-strung length of RG-142 coax. I needed to feed a 20 AWG power lead for the unit at the same time, so I combined the jobs by using the coax to pull the new wire through the wing conduit.
 
Jan 07, 2011     Comm antennas; Cockpit lighting - (4.1 hours)       Category: Electrical
Another milestone! Tonight was the first night I've worked on the airplane in a heated hangar since 2003. It's wonderful being able to crank up the thermostat and work in shirtsleeves.

I fabricated the pair of back-plates for the two comm antennas, and began figuring out where I'll be mounting the antennas.

I also located and drilled the holes for the two mini map lights that will shine on the throttle quadrant and right-side switch panel. These will reside on the forward sides of the vertical channel caps, way up high, under the top longerons.


 
Nov 12, 2010     DVR; Alternator controllers - (3.0 hours)       Category: Electrical
Today I painted and assembled the shelf for the DVR power supply (see previous entry). It will be mounted in the airplane after most of the wiring is done under the aft baggage area.

Next, I installed four 1/4" nutplates on the avionics bulkhead and bolted on the two B&C alternator controllers.


 
Nov 10, 2010     Magnetometers; DVR power supply - (6.0 hours)       Category: Electrical
Today I fabricated a small shelf for the Digital Video Recorder (DVR) power supply. It fits under the right side of the aft baggage compartment's "hat shelf," just forward of the elevator bellcrank. I made it out of 0.40" scrap, with two stiffeners underneath, and two nutplates. It wasn't initially obvious, but the two longerons I decided to mount it to are not in the same dimensional plane. Therefore, I had to bend one mounting tab up, and the other one down. (You might be able to see this in the second photo below.) The shelf is now primed and ready for the nutplates. I'll have to clean up the wiring that passes underneath it before I install it for good.

The big job of the evening was the final installation of the two GRT magnetometers in the aft fuselage. I inserted myself and spent a couple of quality hours in the aft fuselage (with numerous swear words being uttered, I assure you). I only had to get in and out of there about 40 times in order to get tools, tie wraps, different hardware, etc. I was able to successfully make the magnetometer wiring harnesses cross the other nearby wire bundle at a 90-degree angle, as you can see in the third photo. The shelf I made over a year ago is very strong and probably way overbuilt. The only snag was that the BSPQ-44 pop rivets I used to install the shelf could not be pulled from the top because of the tight arc in the top fuselage skin, so I had to insert the rivets from the bottom. I also found out that it's hard to tighten the D-sub connector screws on the back side of a magnetometer using a mirror, worklight, and a small screwdriver when you're a big guy and you're inserted into a space smaller than a coffin.

Photo 1: This small shelf will hold the DVR power supply at left.
Photo 2: It will live here, just forward and right of the elevator bellcrank.
Photo 3: Both GRT magnetometers are now installed and their wiring harnesses are in.

[Superseded.]


 
Nov 10, 2010     Wiring; Avionics rack; Misc. - (4.3 hours) Category: Electrical
Did a bunch of miscellaneous tasks today, most of which relate to electrical stuff (which is why I filed this entry under that category...)

1. Drilled more holes in the under-floor bulkheads and spar, and installed grommets.
2. Ran autopilot servo harness a bit further though the fuselage.
3. Prepped the two magnetometer harnesses for installation.
4. Drilled for nutplates for the right side map pocket. (Most of these nutplates will be in the fuselage, with two in the right vertical channel cap.)
5. Sanded, prepped and primed the channel cap and the map pocket itself.
6. Deburred and prepped the final components of the avionics rack, in preparation for anodizing.
7. Prepped fuselage for installation of both comm antennas.

I also spent some time trying to figure out where and how I'm going to mount the small antenna for the Monroy ATD-300 Traffic Watch unit. It's a stick-type transponder antenna, and it needs to go forward of the wing, on the belly someplace. [Superseded.]
 
Nov 09, 2010     Avionics ground bus (v.1); Other wiring - (2.5 hours)       Category: Electrical
Today, I finished the construction of an avionics ground bus (version 1). I soldered the ends of two 14AWG ground wires across all 25 pins on the back of the male D-sub socket, strain-relieved the wires, ran them out a grommeted hole in the case, and sheathed them in nylon wrap. The box will be mounted once the top skin is riveted in place -- some day far down the road.

I also ran a couple more wires from the aft fuselage to the panel area (DVR power, specifically), ran the smoke oil line the rest of the way through the airplane to the engine compartment, drilled a few more wiring holes through various bulkheads and the spar, and installed a few more rubber grommets.

[Superseded.]


 
Nov 08, 2010     Wiring; Avionics ground bus (v.1) - (3.0 hours) Category: Electrical
Today, I began the construction of a neat little enclosed version of Bob Nuckoll's avionics ground bus that he mentions in his book, "The AeroElectric Connection." I enclosed a set of mated 25-pin D-Sub connectors inside a small metal project box. I riveted in a pair of nutplates to mount it to the avionics bulkhead. More tomorrow.

[Superseded.]
 
Nov 05, 2010     Wiring prep - (.5 hour) Category: Electrical
With the help of my friend Eric, We made a twisted-pair wire harness using a cordless drill. This will be used to power the airplane's DVR recorder.

[Superseded.]
 
Nov 03, 2010     Avionics hub mount - (1.8 hours)       Category: Electrical
Part 1 of tonight's work: I installed the Approach Stack avionics hub to the forward avionics bulkhead using nutplates and #8 screws. (Actually, the backplate is the only part that was permanently mounted. The hub itself will be attached later, after a lot more of the messy work is accomplished.)

To the left of the hub, you can also see the 1/4" mounting holes I drilled for the two alternator controllers. These will get nutplates, too.


 
Nov 02, 2010     Fuselage wiring - (3.5 hours)       Category: Electrical
Lots of progress today. I installed about a dozen pass-through holes and snap bushings in the fuselage under-floor area for the wires that will run from the aft baggage area forward. Then I ran the first half-dozen wires/coax cables along their proposed routings. I identified several places where I'll have to get creative with standoffs and such, but basically everything should be straightforward.

The toughest part of wiring a modern, advanced technology homebuilt is making sure you comply with the avionics manufacturer's requirements for EMI/RFI (Electromagnetic Interference / Radio Frequency Interference.) Certain units have minimum distances from power cables, and other units' mounting requirements do not necessarily allow you to make this happen all the time. Everything is a compromise, but you just do the best you can. For instance, where possible, I've tried to make the power wires cross any coaxial cable at a 90-degree angle to minimize interference.

I installed the ELT for what I think is the final time, and also installed an Adel clamp on the forward end of the aft fuselage wiring conduit, securing it to the sidewall.

Finally, I installed a BNC connector (and a 90-degree adapter) to the end of the transponder coax and attached it to the belly antenna.


 
Oct 31, 2010     Transponder antenna; ELT; Strobe pack removal - (3.5 hours)       Category: Electrical
I got back into the process of wiring the airplane today. I began by installing the Comant CI-105 transponder antenna on the belly. I mounted it about 8 inches aft of where the autopilot pitch servo will be located. I also began running the RG-400 coax from this location forward. I'll crimp on the connector soon, but I need to buy a BNC angle connector first.

Next, I removed the old 4-conductor ELT phone cable and installed the new, thicker 6-conductor cable. [Superseded.]

As is always the case when I squirm into the aft fuselage, things take a lot longer than I think they will. On several occasions, I had to extricate myself to get a different size wrench or a different tool I needed. It's not easy to get in and out of there, and I will be very happy to someday remove the work-floorboards for the last time. While back there, I re-ran some of the wiring in the aft fuselage, added an Adel clamp or two, and prepped the magnetometer shelf for installation.

The final project today was to remove the strobe power pack, since I've decided that LED technology is now the wave of the future -- and dragging 5 pounds of power pack around is simply a waste. It pained me to remove the nice mounting plate I'd created (leaving the attach angles in the airplane to be admired for years to come...) but such is the price of progress. Maybe someone else can use the unit.


 
Oct 13, 2010     Forward bay "black box" rack - (1.7 hours) Category: Electrical
Today I began prepping all the components of the rack for anodizing. I spent a lot of time deburring, sanding and cleaning the parts, and most of them are ready to go. I might drill a couple more mounting holes before I send them off.

I also finalized the method I'll use to mount the bottom rails to the floor. Thanks to some close quarters, it looks like I'll have to use two pairs of Cherry rivets. They will work just fine; I just won't be able to remove the rails as easy as I'd wanted to. (Not sure why I'd want to.)

[Superseded.]
 
Sep 21, 2010     Forward bay "black box" rack - (1.5 hours) Category: Electrical
Drilled out all the remaining rivet/bolt holes to full size. Countersunk nutplate attach holes. Deburred all parts.
 
Sep 17, 2010     Forward bay "black box" rack - (.6 hour) Category: Electrical
Disassembled rack and began drilling all rivet/bolt holes to full size. Drilled holes for nutplates that will attach upper level to lower level.
 
Sep 11, 2010     Forward bay "black box" rack - (2.0 hours)       Category: Electrical
Today I drilled the remaining rivet/bolt holes on the avionics rack, and fabricated a pair of support strips that will be riveted to the bottom center of the fuselage attach rails. These strips will help carry the weight of the various black boxes, instead of the two support rails acting as a long cantilever bridge, and carrying the entire load only at their ends. The strips will simply rest on the floor.

I drilled out the six holes for the AN3 bolts that will attach the upper layer to the lower rails, and began drilling these holes for six #10 nutplates.


 
Aug 27, 2010     Forward bay "black box" rack - (2.9 hours)       Category: Electrical
Today I drilled the attach rails for the rack into the longerons on the floor of the "hell hole," and also began drilling the holes for the various bolts that will hold the rack together. This will probably be the single most complicated modification I've made for this airplane, but it'll be worth it, knowing that all the electrical black boxes will be sturdily-mounted and easily accessible for maintenance.

I've decided to move the EFIS backup battery to the top level of the rack, since it's the most likely of the units to ever need replacement. Since it's also the heaviest unit by far, this is another reason I'm glad the rack is built very robustly.

[Superseded.]


 
Jul 11, 2010     Forward bay "black box" rack; ELT - (.6 hour)       Category: Electrical
All I had time to do today was make a pair of end braces and a diagonal brace for the Black Box rack. A second diagonal brace will go on the other side of the rack, slanted the same direction. Today's new braces were all made from 0.050" x 1" stock.

I've begun planning how this entire structure will be assembled, where the nutplates will go, etc.

Today, I also removed the "old" 121.5 MHz ELT and sent it back to Ameri-King for a $50 rebate. I received my new 406 MHz ELT. The new antenna fits just fine in the same aft bulkhead location I used for the other ELT, and luckily the original mounting setup will work. The only thing I'll have to do it replace the existing 4-conductor RJ-11 control cable with a new, 6-conductor RJ-12 wire. Luckily, I haven't installed it all the way to the cockpit yet.

[Everything superseded.]


 
Jul 05, 2010     Forward bay "black box" rack - (1.4 hours)       Category: Electrical
Now that I've decided to make the avionics black-box rack a "double-decker," I did some work on it today. I cut the 4 vertical support pieces, and also the two main support rails for the upper level.

[Superseded.]


 
Jun 28, 2010     Forward bay "black box" rack - (1.6 hours)       Category: Electrical
Tonight I continued engineering a mounting solution for the various electrical boxes that will go in the "hell hole." I started by cutting the two base rails to fit between the existing floor angles. These will be attached to the floor with rivnuts and screws, and supported with bridging shims underneath, so they don't try to bend under the load they'll be carrying. Another angle will be riveted or bolted to this one (as shown in the photos) to form horizontal attach surfaces for the backup EFIS battery. Other boxes will be on small attach plates.

But that's only half of it. There will be a removable second layer, over top of the first one. I'm going to build a box-like structure with two levels. If I do it carefully, there will still be plenty of room for the alternate air cable and a few other electrical items to be mounted on the side walls.

I can tell there are going to be a LOT of wires in this compartment.

[Everything except the two mounting rails was superseded.]


 
Jun 27, 2010     Forward bay "black box" rack - (2.0 hours)       Category: Electrical
Since I recently took delivery of my EFIS backup battery, which is the heaviest and largest of the boxes that will go in the electrical "hell-hole" under the forward baggage compartment, I decided to begin designing the mounting system that will secure all the various units in place. I wanted to make sure each of the various units could be accessed and removed easily, and utilize as much of the surrounding aircraft structure as possible. It's not easy to do this in the limited space available, and there are some interesting roadblocks in the RV-8 fuselage. The biggest one is that the lower right-side longeron is actually tilted about 20 degrees, which makes it very difficult to tie into. I decided the job could be accomplished using just the forward and aft floor angles.

I laid out some 0.060" angle and began playing around with various configurations that might work, eventually coming up with a twin-rail mounting scheme that will allow for flexible mounting of any size of box, in nearly any orientation. It will also allow me to create a second, removable layer if I need it. (And I think I might...)

It's a challenge to add a structure like this to a finished RV-8, because there's no access under the floor. I'll have to use rivnuts to attach the support angles to the floor, with spacers used to support the angles mid-span (between the support angles and the floor). That's the plan right now, anyway. It's all subject to change as I develop it.

Photo 1: The two smaller boxes will be mounted to base-plates that are screwed into the rails.
Photo 2: The bottom angles will be attached to the floor with rivnuts. Bolts will attach the side rails.

[Entire plan superseded.]


 
Jun 21, 2010     Tail wiring; "Black box" location survey - (1.8 hours)       Category: Electrical
Today I cleaned up the wiring under the vertical stabilizer where the VOR antenna wire and the tail camera wire make their way from the VS down into the fuselage. This area has a lot of sharp edges and twists & turns, so I had to use thick-wall plastic tubing to protect the wires in several places. The two wires are zip-tied to an adhesive mount on the top of the horizontal stab spar.

I also spent a bit of time figuring out exactly where I'll be locating some of the electrical "black boxes," namely the Safety Trim box, the lighting controller, and the EFIS backup battery. More to come.


 
Jun 16, 2010     VOR antenna coax - (.7 hour)       Category: Electrical
The VOR puck antenna on the top of the tail was fitted with a long coax lead, and today I cut off about three feet of excess and fitted a new male BNC connector to it. Then I cut off the excess from the RG-400 coax running through the fuselage and crimped on a female connector. Once the union was made, I heat-shrinked the connection.

I will have to secure the leads a bit (along with the video camera lead nearby). Not sure how I'll do that, but I'll figure it out later.


 
Jun 13, 2010     Elec system redesign and switch panel mods - (5.5 hours) Category: Electrical
Over the past couple of days, I have managed to eliminate a couple of switches from the main switch panel, which will also allow me to simplify the panel layout and the electrical system itself. The EIS power switch has been eliminated entirely. I also moved the nav lights switch to the main instrument panel. This necessitated several other changes to the panel, which led to more diagram changes... you know how it goes.

The EIS will be controlled with the same switch as the EFIS/AHRS units. It barely uses any current, so it will be OK to add to the Essential Bus.

Redesigning the electrical system is somewhat tedious work, but I actually enjoy most of it. Thinking things through at this final stage before wiring the airplane will pay dividends later.
 
Jan 26, 2010     Electrical system revisions - (2.5 hours) Category: Electrical
Did more revisions of the electrical system and switch panel. The function of the EFIS Backup Battery switch will now be different, and it won't require a switch guard like before. Instead, it will be a locking toggle switch. This means its location had to be moved slightly. [Superseded.]
 
Jan 25, 2010     Electrical system revisions - (4.0 hours) Category: Electrical
Today I revised the electrical system to accommodate a new product by TCW Tech that solves several design issues in one box. They are now marketing an integral backup battery and switching unit that I plan to use for my EFIS backup power supply. It's called the IBBS-12v-4Ah. [Superseded.]
 
Jul 19, 2009     Tail wiring - (1.5 hours)       Category: Electrical
It was another pretty productive day buried up to my ankles in the tail cone. I completed all the little cleanups of the wiring back there, ran the ELT control wire through the aft baggage bulkhead, and drilled about a dozen holes and temporarily attached Adel clamps in preparation for routing the strobe and nav wires, magnetometer wires, autopilot cable, and DV camera wire. I also cleaned up and secured all the remaining wires under the aft deck.


 
Jul 18, 2009     ELT wiring; Aft wire cleanup and clamping - (3.4 hours)       Category: Electrical
I spent over three hours deep in the aft fuselage today, a place I hope I will shortly not have to revisit ever again. :-)

Tasks accomplished:

- Modified work floorboards so they'd fit with new Adel clamps and autopilot servo in place.
- Added second tie-wrap to mid-conduit support.
- Installed ELT. [Superseded.]
- Installed ELT antenna coax cable along left side of fuselage. Aft to forward, it is supported by the bulkhead connector, a stick-on tie-wrap base, a rubber grommet through a bulkhead -- then it's tie-wrapped to the static line the rest of the way. I generally don't like stick-on tie-wrap bases, but there simply is no other way to install a clamp way back there.
- Plugged RJ-11 remote control wire into ELT and began running it forward. Installed the first of several Adel clamps for this wire. Drilled holes for several more. [Superseded.]
- Installed strobe power unit. [Superseded.]
- Repositioned static line around strobe unit. Added anti-chafe tubing and Adel clamps to keep it clear.
- Drilled holes in old strobe-mount angles for several Adel clamps that will support the magnetometer wires.
- Installed two Adel clamps in the tail cone. One is the right lower longeron and the other is in the edge of the large lightening hole in the aft deck. These will keep the tail wiring well away from the elevator pushrod.


 
Jul 02, 2009     Tail wiring - (.5 hour)       Category: Electrical
Today I received the 5-conductor wire for the elevator trim, so I bundled it with the others, taped the bundle to the pull-string already in the conduit and pulled them all through. I then fed the strobe and nav light wires through the grommets in the two aft bulkheads, and installed a hole edge grommet in one of the lightening holes in the horizontal stabilizer, where the trim wire will pass through. (It will also get wrapped with spiral-wrap in that area.)

[Black camera cable superseded.]


 
Jun 26, 2009     Prep for pulling wires (tail) - (.4 hour)       Category: Electrical
This evening, I had time to lay out the various wires that will go through the tail conduit. I used a vacuum cleaner to suck a pull-string through the conduit, then taped the wires into a bundle that I'll pull forward through the conduit. (I'm still waiting on a 5-conductor wire for the elevator trim servo. As soon as it arrives, I'll pull the wires).

Wires to be pulled:
-- 5-conductor shielded wire for Ray Allen elevator trim
-- VOR/GS antenna coax
-- 4-conductor tail camera harness [Superseded.]
-- 3-conductor shielded wire for strobe light
-- Nav light power
-- Common ground wire for lights [Superseded.]


 
Jun 15, 2009     Rear cockpit power port - (.5 hour)       Category: Electrical
Installed the Powerlet socket in the rear cockpit. To maintain the desired military theme of the airplane, I used black socket-head cap screws to attach the backing plate, and it came out looking pretty nice, in my opinion.

[Superseded.]


 
May 24, 2009     Tail wiring - (.2 hour)       Category: Electrical
Measured coax and power wires that will run from the tail to the cockpit.


 
Apr 11, 2009     Firewall grounding block - (.9 hour)       Category: Electrical
All I had time to do today was install the firewall-mounted grounding block. I'm using a 48-position brass block from B&C. The large pass-through bolt is located very close to the negative terminal of the battery, so the cable run will be short. Every electrical item in the airframe (except avionics) will ground directly to this block. The avionics will have a dedicated avionics ground bus. [Superseded.]

The second, smaller attach bolt, an AN-3, had to be installed with the head on the back side of the firewall because of the narrow slot the block's mounting hole is in. I didn't have a proper high-temp hardware for it, so I'll have to change it out later.

I spent the rest of the afternoon getting my shop back into some semblance of order. It's been getting cluttered and messy lately.


 
Feb 10, 2009     E-Bus diode wiring - (.3 hour) Category: Electrical
I began fabricating the wires connecting the main and Essential buses through the Schottky diode. These are short, 10 AWG connections with PIDG ring terminals on each end.
 
Sep 02, 2008     Electrical buses - (.2 hour)       Category: Electrical
The avionics access door finally looks the way I want it, so I mounted the Main and Essential buses and Schottky diode to it.

[Superseded.]


 
Aug 15, 2008     Front cockpit power jack - (.4 hour)       Category: Electrical
Today I installed the 12V power jack in the right mid-cabin cover, next to the previously-installed aux battery charger jack.

[Superseded.]


 
Jul 23, 2008     Electrical buses - (.5 hour) Category: Electrical
Located and drilled mounting holes on avionics access door for Main and Essential buses and Schottky diode. Painted avionics access door.
 
Jul 16, 2008     What's on the Buses? Category: Electrical
These items are powered by the Essential Bus:

1. Both of the EFIS Displays, AHRS, EIS, and magnetometer. (Low current draw, and these are my main flight instruments.)
2. Garmin 430W (My primary Comm/Nav/GPS)
3. Autopilot (In a critical IFR emergency, an autopilot is a HUGE help in keeping task-saturation levels low.)
4. Transponder (They can't vector you if they can't see you.)
5. A backup starter switch, located on the panel. (Several reasons for this: In the event of a Master Contactor failure or stick-mounted starter switch failure, I can power the E-Bus from the battery using a "Battery Direct" switch, so I can still start the engine and taxi myself to the shop. Also, in the event of an inflight, time-critical need to hit the starter, I don't have to fumble around for the normal "Start Arm" switch first -- I just hit the panel-mounted button.)

These items are powered by the Battery Bus:

1. E-Bus (through a relay and switch).
2. Cockpit lights (It's nice to reach in and get some lights on quickly).
3. Power socket (Allows charging of main battery in the hangar).
4. Garmin SL-30 (Nice to get ATIS and clearance before engine start).
5. Avionics "keep alive" circuits.

EVERYTHING else is powered from the Main bus.

The GRT EFISs can also be powered from a 7.2Ah battery, and the Dynon D-10A has its own internal battery, too.

[Note: Some items have been superseded, and several slight detail changes were made later on -- but this is still the basic architecture I went with.]
 
Jul 15, 2008     My "Essential Bus" philosophy Category: Electrical
Let's talk E-Bus!

Some people install what they call an "Endurance Bus" in their airplane. They define the function of an Endurance Bus by stating its function -- to "continue the flight to the original intended destination," and then use battery power to make the landing.

I have a problem with this concept. If my "original, intended destination" was a 1500'-long turf runway in the wilds of Idaho, with no services and no maintenance available, then I humbly propose that continuing to the original intended destination constitutes poor airmanship. Now you're stuck in the middle of nowhere with a bad alternator or contactor or whatever.

My backup bus is called an Essential Bus. My personal interpretation of this is: A power source that will get you safely and comfortably to the nearest suitable airfield where repairs can be accomplished. Maybe not with full-up instrumentation and all your electronic goodies and lights running, but with a carefully chosen batch of them. I call it an Essential Bus because that's what it is -- the essentials.

Note I didn't say "the nearest airport," I said the nearest suitable airport -- someplace with a maintenance shop, available transportation to take me to a nearby hotel, a stocked Pepsi machine, reasonable weather and wind conditions -- whatever I deem "suitable" in that particular situation.

As a responsible pilot, I will not over-fly a suitable airport when I have a known malfunction with my airplane. You can casually toss that concept out the window if you want, but I'm still here after flying 13,000 hours and 115 aircraft types, including military, experimentals, and warbirds. Works for me. Works for the military. Works for the airlines.

Just throwing it out there.
 
Apr 02, 2007     Nav light; Wire labeling - (.3 hour)       Category: Electrical
Fastened nav light power puck onto outboard rib with #6 screws, washers and nyloc nuts.

Heat-shrunk labels onto inboard end of lighting wires.


 
Mar 15, 2007     Wing wiring - (2.1 hours)       Category: Electrical
Fastened wingtip wiring bundle to end rib with two Adel clamps. Connected wires for landing light and nav lights. Attached ground side of each circuit to end rib with bolt/washer/nut. Soldered pitot heat wires to connector. Labeled all wires.


 
Mar 04, 2007     Annunciator panel - (1.8 hours)       Category: Electrical
I finished trimming both front and back channels of the annunciator. Also trimmed off some additional material on each end to leave the tabs where the unit will mount to the panel. (The idea is that I will run two long screws through the instrument panel, one at each end of the annunciator. These screws will then go through the tabs on the front channel, then through about 5/8" of empty space between the tabs, then through the tabs on the back channel, and it'll all be held together with two Nyloc nuts.)

Sandwiched between the two channels, of course, will be a thin Lexan sheet with the light legends printed on them.

The dividers are held in place with a tight fit, and also with dabs of E6000 clear adhesive. (The second photo below shows them held with blobs of "hot glue," but this didn't work out as well. The E6000 is much more robust.)


 
Feb 19, 2007     Wing wiring - (1.1 hours)       Category: Electrical
Continued wiring left wing. Pulled wires for pitot heat and Dynon magnetometer harness. Marked location for future Adel clamps on end rib. Marked all wires with heat-shrink labels. (To do this, I use a neat printer called a Dymo RhinoPro 3000. Highly recommended!)

I also began fiddling with various aluminum channel pieces that will eventually become my annunciator panel.


 
Feb 17, 2007     Wing wiring - (.5 hour) Category: Electrical
Began wiring the left wing. Pulled wires for the nav lights and the landing lights.
 
Nov 27, 2006     OAT probe (secondary) - (1.1 hours)       Category: Electrical
Installed the left wing OAT probe. This is the probe for the Dynon D10A EFIS, which will be my backup flight instrument. I located and drilled a 3/8' hole near the middle access panel using a Unibit. Deburred and primed the hole, then mounted the probe with nylon washers. Installed an Adel clamp for the probe's wire on a nearby rib so the wire will clear the large aileron pushrod. I ran the wire outboard through pre-existing plastic bushings to the wingtip rib, where it will connect to the Dynon remote compass.


 
Sep 26, 2006     Tail LED Light - (.8 hour)       Category: Electrical
Disassembled and modified a stock Whelan A555 light assembly to accept my new Perihelion LED tail light unit. I cut off all but about 1/2" of shroud. (The instructions say to cut it all off, but leaving a bit of the flange appears to help keep the LED unit aligned and supported better.)


 


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