Oct 21, 2023     Firewall insulation and passthrough - (2 hours) Category: Firewall

Prepared two stainless steel strips to be riveted to the firewall inside the oil cooler mount. They will keep the fiberfrax and steel foil in position. Used Firebarrier2000 inside the oil cooler mount.

  Oct 14, 2023     firewall insulation and passthrough - (0.5 hour)       Category: Firewall

little modification of the steel air vent valves. Attached two nutplates to avoid the use of a metal lock nut.

  Oct 12, 2023     Firewall Insulation - (4 hours)       Category: Firewall

Final installation of the fiberfrax panel.
Cleaned the steel foil, used firebarrier2000 to create a fillet around the firewall perimeter and around the engine mount. Used wooden bars to keep the fiberfrax/steel foil attached to the firewall.
Prepared the Steel Eyeball passthrough for the 4 bowden cables (drilled to the right diameter for each passthrough).
Modified the steel cabin air vents installing a nut plate on each valve to simplify installation of the cable clamp.

  Oct 10, 2023     firewall Insulation - (3 hours) Category: Firewall

Cleaned the firewall and the fiberfrax halves. Final trimming of the fiberfrax halves. Positioned the right half and glued to the firewall. Positioned the left half and trimmed. Used spray glue to position the left fiberfrax. Lucio drilled holes for the oil recess fiberfrax angles after checking proper fitting. Deburred holes.

  Oct 10, 2023     28-13 Fwd Fuse Ribs, BHDS & Bottom Skins Step 1-4 - (1 hour) Category: Firewall

The firewall has not been riveted to the bottom and side skins. After riveting the piano hinges to the side skins i had to rivet the bottom skin to the firewall (except the hinges and the center rivet that will be used for a bottom cowl bracket.

  Oct 07, 2023     43-10 Cabin Cover step 8 - (1 hour)       Category: Firewall

Trimmed the cabin strut and the channel to remove interference with W-1042L/R top part. The paint shop added some material to smooth out the fiberglass but it created interference and the top cover was not sitting properly.

  Oct 07, 2023     Installation of nutplates for ANL and Shunt - (1 hour)       Category: Firewall

Installed nutplates

  Oct 06, 2023     Passthrough Installation - (4 hours)       Category: Firewall

Drilling for the installation of ANL 60A for main alternator and its shunt and of the ANL 40A for the backup alternator and its shunt. Drilled the platenuts holes.
It took a long time in order to check interference with engine mount and transducer block and other firewall installed parts.
Thanks to Lucio for the precious advice as usual.

  Sep 18, 2023     Firewall insulation and passthrough - (1 hour) Category: Firewall

rechecked position of passthrough. Riveted passthrough

  Sep 06, 2023     firewall Insulation and passthrough - (2 hours)       Category: Firewall

Fabricated a small steel fairing for the air vent valve cables. I had redo the fairing as the previous one was too small.
Same process. Initially thought to rivet to the firewall, but then changed my mind and i will install to nutplates (-8 screws).

  Sep 05, 2023     firewall Insulation and passthrough - (6 hours)       Category: Firewall

Installed additional passthrough. Defined position for Main Passthrough and ANL / SHUNT.
Decided to trim the fiberfrax to allow direct riveting of oil cooler mount to the firewall. Trimmed fiberfrax to allow direct contact of engine mount to the firewall.
Fiberfrax should not be sandwiched between riveted items as with vibration the fiberfrax loosen up and rivets are not holding tight.

  Aug 30, 2023     Metal fairing for cabin air control cables - (4 hours) Category: Firewall

Thinking about building a little fairing for the cabin air cables penetration. Idea is to rivet it on the fiberfrax and fill it with Firebarrier2000 instead of leaving the two cables just there with a little bit of RTV as suggested by VANS.
I did a mock up in aluminum just to see how it could fit.
I need to create a little tool to facilitate the forming of the steel foil taken from the oil recess part that i screwed up earlier in the project
Aluminum mock up seems to be ok.
Carved an hard wood block with the shape and formed the fairing, Deburred and cut to measure.
Lucio agrees this is a valid solution and a better way to manage this passthrough compared to the solution proposed by VANS

  Jul 28, 2023     46-2 Engine Mount and landing gear Step 1 - (3 hours) Category: Firewall

Preliminary installation of steel passthrough on the firewall for the AWG2 wire to the starter contactor and for the AWG8/AWG6 from starter contractor to main bus.removed the engine mount to facilitate drilling. Removed oil cooler for easier work.
Riveted brake line bracket to the rudder pedal brace (F-1039D). I made the brake line bracket in an earlier step and i needed help to rivet in place due to the awkward position.

  Jun 30, 2023     Various consideration on Firewall - (5 hours)       Category: Firewall

Based on Lucio's experience we addressed few aspects of firewall penetration and passthrough locations.
1. Penetration for AWG2 wire to starter contactor. Changed the position compared to the original drawing to allow use of steel passthrough.
2. Penetration for Engine Sensors : using two large avery passthrough positioned on the top of the firewall away from the oil filter to allow easier replacement
3. Penetration for Cabin Air Heat Valve: Lucio will prepare a passthrough with angled tubing.
4. Penetration for Manifold Pressure sensor not required as Garmin Sensor will be positioned on the VA-168 Sender Mount using the available slot (one for oil pressure, another one for fuel pressure and the last for manifold pressure)
5. Replace Fuel Aluminum fitting with steel fitting (same shape) AN837-6 steel
6. Grounding block for ring connectors on both sides of the firewall
7. Grounding block for ring connectors on the sub panel. Connect with AWG8 to Firewall grounding block?

  Apr 22, 2023     Firewall Insulation - (4 hours)       Category: Firewall

Removed all the accessories from the firewall. Dimpled the holes on the Oil Cooler support even if not strictly necessary as i will be sandwiching steel/fiberfrax when riveting.
Reinstalled the Oil filter recessa after dimpling and riveting the flanges to itself.
Asked Chiara to do the riveting and everything turned out fine.

  Apr 21, 2023     firewall Insulation - (2 hours)       Category: Firewall

Preliminary installation of the two firewall insulation panels, checked installation of oil cooler support, transducer, brake reservoir, cabin air vents and contractor. Cut remaining holes, deburred the steel foil where necessary.
Even though i used the gloves i had to pay another blood sacrifices to the Gods of Steel Sheet

  Apr 18, 2023     firewall Insulation - (4 hours)       Category: Firewall

Prepared the two fiberfrax parts and cut the right foil. several attempts to fit and trimmed. Glued the foil to the fiberfrax right side and positioned on the firewall. Used masking tape to hold in position. Marked the holes and cut the holes with a cutter. deburred and reinstalled the brake reservoir and the air valve (right).
Blood tribute paid to the God of Steel.

  Apr 17, 2023     Firewall Insulation - (4 hours)       Category: Firewall

Cut the fiberfrax to measure. cut the stainless steel foil to measure. Positioned the foil and drilled the holes using the recess screw holes.
Installed the spherical firewall fitting flange and matchdrilled.
After sandwiching the fiberfrax and steel foil between the spherical firewall fitting flanges i used a cutter to create the hole for the ball passthrough.
Trimmed the fiberfrax and stainless foil.

  Apr 14, 2023     Firewall Insulation - (3 hours) Category: Firewall

Trimmed the fiberfrax to size leaving 1/8" between the firewall flanges and the fiberfrax. Trimmed the recess fiberfrax flanges.
Tested the installation of the EYEBALL FIREWALL FITTING- SS PRESSURE PLATE - STEEL TTP. Cutting the steel foil with a cutter once squeezed between the eyeball flanges is pretty easy. Drilling holes for the screws with #30 is not enough, better use a #21 through the eyeball flange
End result is very nice, need to replicate on the final fitting.
Ordered the fire barrier 2000 sealant.

  Apr 11, 2023     Firewall Insulation - (3 hours)       Category: Firewall

Following Dan Horton advice i decided to install a fiberfrax insulation covered with a stainless steel foil. Dan provides a full kit, however import duty, shipment cost make it impractical to acquire here in Europe.
I started with a mock up made of 1/8 thick foam purchased at the local store. I marked and cut following the firewall contour and the oil filter recess. After fitting and trimming the foam mock up i moved into cutting the fiberfrax.
Using the same method i cut the fiberfrax parts for the oil filter recess.
I also tested the scissors on the stainless steel and they work much better than the aluminum scissor i got. precise cuts and very precise on the trimming.

  Apr 05, 2023     27-2 Firewall step 1-5 Recess Replacement - (4 hours)       Category: Firewall

Final preparation of the Firewall recess and drilling for the installation of 4 Ball bearing (Mixture control, Throttle, Propeller pitch and alternate air)
As usual Lucio did a great job