Project: Voltar-S21   -  
            Listing for Category : avionics
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Builder Name:Vern Little   -  
Project:   Rans - S-21 Outbound   -   VIEW REPORTS
Total Hours:2315.8
Start/Last Date:Mar 06, 2018 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=Voltar-S21

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Apr 27, 2024     Boot Cowl Grommets & ELT - (2.0 hours)       Category: Avionics
Attached ELT antenna. ELT installation now complete, just needs to be registered online and tested.

Modified openings on boot cowl to clear downtubes, and modified grommets to allow edge distance for rivets. Used heat gun to shape grommets and have them lay flat to the boot cowl. Because of the way the boot cowls fit, the gaps to the downtubes are not symmetrical, but it shouldn't be a problem, once the glareshield material is in place.


 
Apr 26, 2024     ELT Doubler, Cable Exit Fairings - (3.5 hours)       Category: Avionics
Wet riveted ELT skin doubler in place. Primed area where ELT antenna mounts to exterior skin. Also, primed glareshield where it fits under boot cowl. Groomed ELT wires.

Trimmed steering cable exit fairings and fit to fuselage. The fairing flanges were sanded to about 3/64”. When attached using the #8 Screws, nutplates and 3/32” diameter pull rivets, the domed heads of the rivets protrude enough so that they support the fairing at about the same height as the flange. When the attachment screws are tightened, these support the fairing just enough to prevent warping. I may also use washers glued to inside of fairings to prevent warping the fairings.


 
Apr 25, 2024     ELT Antenna - (3.5 hours)       Category: Avionics
Groomed ELT wiring and fabricated a 0.032” 2024-T3 doubler for ELT antenna that stiffens the skin. The doubler has joggled edges to fit over the bulkhead and former/longeron and be riveted in place to the existing structure. I will also use a 2” diameter 0.040 round disc under the antenna. Primed doubler with Super-K. The purpose of the doubler is to minimize skin buckling and relieve stresses on the bulkhead/longeron rivets. I may also add rivets for additional strength.

Also, rough trimmed rudder cable fairings. Starting to complete small jobs in preparation for canopy work.


 
Apr 24, 2024     ELT Install - (2.0 hours)       Category: Avionics
Mounted ELT antenna and bonded zip tie mounts inside fuselage. Bought a new trouble light and E6000 adhesive.


 
Apr 23, 2024     ELT Install - (3.0 hours)       Category: Avionics
Connected and tested ELT. Had to redo one connection. Used my oscilloscope to confirm operation. Still need to source the remote battery which is not available off the shelf locally. The rails for the ELT mount were left over from my RV-9A, 2024-T3 channel.

Still need to install antenna.


 
Apr 22, 2024     ELT Install - (3.0 hours) Category: Avionics
Mounted ELT remote, audible alarm and main unit. Wired the DIN connector and tested the connection. Still need to mount antenna and buy a battery for the remote unit.

I had prepped the mounting hardpoints some time ago, and everything fit perfectly.
 
Apr 09, 2024     Taxi Camera - (2.0 hours) Category: Avionics
Installed wiring for taxi camera. Clecoed glareshield back in place. Awaiting delivery of ELT.
 
Apr 05, 2024     GPS Puck - (2.5 hours)       Category: Avionics
Completed GPS puck installation, including wiring and testing. Used a Microfit connector to connect to EFIS wiring.


 
Apr 04, 2024     Bonded Fuel Sensor - (1.7 hours)       Category: Avionics
Bonded fuel level sensor in place. Scuffed sensor and fuel tank with 180 grit sandpaper and bonded with shoe goo. Also drilled for GPS antenna on fuselage and primered with Super-K. Also bonded zip tie mounts to help secure wing wiring harnesses.


 
Apr 03, 2024     Installed Fuel Sensor - (2 hours)       Category: Avionics
Installed wiring for fuel level sensor switch.


 
Apr 02, 2024     Fuel Level Sensor - (2 hours) Category: Avionics
Ran wires for fuel level sensor on header tank. Tapped off of accessory power. Not using the Rans supplied switch, instead using an ultrasonic fluid level sensor.
 
Apr 01, 2024     Wiring Mods - (2.5 hours) Category: Avionics
Finished installation of wing wiring terminal block by riveting it in place. Modified wiring of my pitot heat/horn circuit. Rather than sharing a circuit breaker, I replaced my pitot heat switch with an On-On SPDT unit with the second pole enabling the horn circuit. Now, the horn will only be enable with pitot heat off.

Spent some time sanding my repair work to the wing tips. The tips were damaged during removal, so now I have a lanyard system that prevents them from falling during removal (or attachment).
 
Nov 22, 2023     Lights - (4.0 hours)       Category: Avionics
Finished installation of landing, taxi, strobe and position lights. Tested from panel, everything works as designed. Managed to smash both wingtip trailing edges due to shop mishaps. Will rebuild them with PVC scrap.

Slid landing light lenses into place. Used a block of wood and gently tapped them into place. Nice tight fit. A bit of transparent caulking will weatherproof things later on. I will use Lexel, rather than unpaintable silicone.


 
Nov 21, 2023     Wing Connections - (3.0 hours) Category: Avionics
Routed and connected wing wiring to avionics wiring. More to do!


 
Sep 12, 2023     Avionics Review - (2.8 hours) Category: Avionics
Minor tweaking of avionics to match some changes I made to huVVer-AVI six-pack. Added an option to make one of the huVVer-AVI MFDs into a PMag controller. This involved wiring in a 4-pin Microfit 3.0 connecter to the two RS-232 ports on the huVVer that can plug into either the PMag serial control signals, or the standard instrument streaming data from the SkyView and OnSpeed systems.

Also added a 20K ohm resistor in series with pitot heat sense line, as recommended by Dynon (actually recommended 10K, but 20K works).

 
Jun 14, 2023     PWM Dimmer - (3.2 hours)       Category: Avionics
Decided to implement a separate pilot-controlled dimmer for the glareshield strip light. Scrounged some parts and built a perf board with the circuit. Painted underside of glareshield.

Still considering the dimmer circuit design to make it more robust.


 
Jun 13, 2023     Strip Light - (3.2 hours)       Category: Avionics
Changed the strip light dimmer to a panel mounted control.
Checked brake hoses near rudder pedals for interference and torque.


 
Jun 12, 2023     Strip Light - (1.0 hour)       Category: Avionics
Glued strip-light pass-through in place.


 
Jun 10, 2023     Fan and Strip Lights - (3.0 hours)       Category: Avionics
Cut fan hole in glare shield and trial mounted fan. 75mm square fan and finger guard fits nicely over a 3-1/8” instrument hole, cut by my Greenlee punch. Fan mounted with 1-1/4” stainless machine screws and acorn nuts (to be painted black).

Connected glare shield light strip to EFIS PWM dimmer output. Light strip was so bright that I put a 10 Kohm trimmer potentiometer in series to limit brightness. Adjusted it to match SkyView Screen brightness at low ambient light.


 
Apr 21, 2023     Engine Hoses - (3.0 hours)       Category: Avionics
Rigged oil cooler hoses. Needed to replace one oil cooler fitting with a 90 degree elbow and carefully route the hoses around the PMags. It would be easier to have custom hoses built, but this seemed to work out. A lot of fussing and finagling to get the provided hoses to work.


 
Apr 19, 2023     Engine Hanging - (5 hours)       Category: Avionics
Hung Engine. Looks like back of PMag interferes with starter contactor, so the contactor will be moved.


 
Apr 16, 2023     Modified Ident switch - (0.5 hour) Category: Avionics
Changed Ident pushbutton on panel to an Autopilot CWS button. Updated the switch label and moved one wire in the Panel connector to enable the function.
 
Jan 04, 2023     OnSpeed Reinstall - (2.5 hours) Category: Avionics
Reinstalled OnSpeed black box after circuit board rework and software updates. Noticed some strange operation, not taking the calibration settings. Need to dig deeper.
 
Dec 17, 2022     OnSpeed Repair - (1.0 hour) Category: Avionics
Working on repair of my OnSpeed black box that got wiped out when the EFIS serial ports fried. I found a MAX3232 in stock... but it was an SO package, and I needed a DIP. I also found an adapter board I purchased 10 years ago that I could mount the chip onto, and it fanned out to the DIP pinout. Problem solved, but I did have to wire a couple of jumper wires to repair the PCB.

The original driver chip was a MAX3222, which is an 18-pin device, but the way it is used in the box meant that the 16-pin version would also work!
 
Dec 17, 2022     Wing Skin Shims - (1.5 hours) Category: Avionics
Primed and riveted the shims on my wing tip skins. Eliminated most of the pillowing now.
 
Dec 14, 2022     Securing Wiring - (1.5 hours) Category: Avionics
Secured wiring and connectors behind panel. This involved ensuring that all dsub jackscrews were tight, the wiring harnesses were well secured, and Amp connects were immobilized. Put heatshrink one one disused wire (design change).
 
Dec 12, 2022     Glareshield Instruments - (4.4 hours)       Category: Avionics
Changed my connection scheme for glareshield mounted instruments from 'audio jack and plugs' to Molex Microfit 3 connectors. While confirming the wiring, I noticed that the serial connection from the EFIS to the OnSpeed black box was not functional. Traced it down to a hardware failure in the black box. This may be related to the serial port output failures I had in my EFIS. ESD?


 
Nov 14, 2022     PMag Control Wiring - (3 hours)       Category: Avionics
Completed wiring modifications to support external programming and control of PMag ignitions.

The first diagram shows a simple method of PMag control wiring: P-Lead switches and pullable circuit breakers for testing the internal PMag generators. In discussions with Brad Dement at EMagair, this wiring will support hand-propping if it ever becomes necessary.

For hand-propping, the circuit breakers are pulled, the PLead switches are turned on, then the Master switch is turned on, followed by pushing the circuit breakers in. As long as the main battery has enough energy to turn the master contactor on, there will be enough energy to fire the PMags. This sequence disables the 3-rotation delay that the PMags have for startup.

The timing switch just connects two wires from the PMags together to select timing curve A or B. Selecting curve B is more aggressive, and also allows an external controller to configure the PMags (such as the EI Commander or EICAD on a laptop). I have run these wires to an instrument hole for future control options.

The second diagram shows a huVVer-AVI instrument that can be configured as a PMag controller. This will be a software development after the aircraft is complete.


 
Nov 12, 2022     PMAG Wiring Reprise - (3 hours) Category: Avionics
After a long discussion with Emagair's Brad Dement, I decided to simplify the PMag wiring and just use the Klixon breakers to kill power for testing. I also replaced the switch that was intended to control a MAP air valve with just a curve A/curve B switch connected to the PMag serial lines.

I am also planning on putting connectors on the panel for the L & R PMag serial ports. I'll use the EICAD software on my laptop for PMag configuration and timing customization, connected to these ports. The ports will be on a 2" blank, occupying one of the MFD instrument positions. Eventually, I will develop a complete controller using a huVVer-AVI instrument to replace the external laptop.
 
Nov 08, 2022     Downtube and Engine Mount - (3.2 hours)       Category: Avionics
Wired downtube connectors that provide data and power to glareshield mounted devices.

Slotted floorboard to allow insertion of engine mount bolts.


 
Nov 07, 2022     Rewiring PMAG connections - (3.5 hours) Category: Avionics
Checked the EMag/PMag wiring diagrams, and they recommend using 18AWG wires with 5A circuit breakers. I had 22AWG installed, so I replaced it with 18AWG all the way from the breakers, through the switches and FWF.
 
Nov 05, 2022     Debugging SkyView - (3 hours) Category: Avionics
Removed SkyView HDX screen. Fabricated simple power harness and powered up EFIS with my bench top power supply.

Replicated my diagnosis that Serial 1 and Serial 2 outputs are dead. Boxed up SkyView, ready to ship once I get an RMA number.

Puzzled over what could kill the outputs. RS232 links are very robust, and ESD or overvoltage conditions don't normally damage them.
 
Nov 04, 2022     Debugging SkyView - (3.5 hours) Category: Avionics
Two of the serial ports on the SkyView HDX seem non-functional. Disconnected all loads, still not right.

Next step is remove the wiring harness and check for problems. Everything was fine until the cold Wx. In touch with Dynon, but no joy.
 
Oct 29, 2022     Downtube Power - (1 hour) Category: Avionics
Decided to add power/data jacks to the left and right downtubes. This provides the OnSpeed wiring for glareshield displays based on my huVVer-AVI devices.

These jacks use 4-wire audio cables, repurposed to provide power, ground, data-in, and data-out signals. This is identical to my Harmon Rocket panel jack that I use for my glareshield mounted display.

The advantage of using this audio cable is that it is compact and black-- easy to run forward of the downtubes and won't reflect in the windscreen. I bough two cables, and will cut them in half, so I can get both the plug and jack from one cable.

Now, I can 3D print whatever mounting I need to add instruments connected to the downtubes, or to the boot cowl. For example, a lighted compass, additional huVVer-AVI units, or an OnSpeed/huVVer-AVI for the copilot.
 
Oct 21, 2022     Static Ports - (2.5 hours)       Category: Avionics
Used 1/4 OD/ 1/8 ID fuel line to connect static port rivets to Tee connector.

The Safety wire wrap is unecessary, it's virtually impossible to pull line off the ports without it.


 
Oct 20, 2022     Pitot/Static/AOA - (2.5 hours)       Category: Avionics
Reorganized Pitot/Static/AOA connections between Dynon ADAHRS and OnSpeed IMU. Ran Static line to foward fuse and Pitot and AOA to left wing root.


 
Aug 31, 2022     Grooming Wiring - (4.3 hours)       Category: Avionics
Added connectors to panel PTT and IDENT Lamp/Switches and tidied up wiring with lacing twine.

Rewired Fuel Pump ground wire that did not need to be run through a Molex connector. Connected it directly to ground. This allows a complete panel removal by unplugging all of the Molex and Dsub connectors, and removing the parking brake cable.


 
Aug 30, 2022     Connectorizing - (2.7 hours)       Category: Avionics
Added Microfit 3.0 connectors to panel lamp/switches and panel trim switch.

This will allow easier panel insertion/extraction and minimize component damage.

Still need to connectorize PTT and IDENT switch.

The Microfit pins are tedious to install, and requires special crimp and extraction tools, but they are very light. I use the gold plated pins for low current applications.


 
Aug 29, 2022     Rewired OnSpeed Control - (1.0 hour)       Category: Avionics
Removed control potentiometer from my homebrew board and used the OS PCB for this application. Added a Molex connector to simplify re-installation of the wiring harness.


 
Jul 21, 2022     huVVer-AVI Update - (3.5 hours) Category: Avionics
Added CAN bus wiring to my six-pack of huVVer-AVI devices. Also added EMAG RPM left and right inputs to one device for allow for a future ignition controller.

The CAN bus wiring will initially be used to synchronize dimmers between instruments, so that dimming one unit will dim all of them together.
 
Jul 16, 2022     ELT Tray - (1.0 hour)       Category: Avionics
Installed ELT tray in aft fuselage. Designed for ACK E-04.


 
Jul 15, 2022     Priming ELT Tray - (1 hour) Category: Avionics
Primed ELT tray and miscellaneous parts.
 
Jun 11, 2022     Wire Grooming - (3.0 hours)       Category: Avionics
Getting near the end of wire grooming. Added backshells and tightened dsub connector screws. Added sheathing to FWF wire bundles. Checked out trim control and trim position sensor.

Need to check my autotrim controller, it seems to be making trim corrections on the ground, without the autopilot engaged. Can just be a SkyView configuration issue, but I doubt it. I turned of the System stream (just using ADAHRS and EMS streaming data. That should have turned off trim corrections, but did not. I suspect it's a coding error... back to code debugging. I can also plug in my PC and change a bunch of settings on the controller.

The trim controller is based on the one I designed in my Harmon Rocket, except that I removed the real-time interrupt loop for the ESP-32 implementation.


 
Jun 10, 2022     Wire Grooming - (2.0 hours) Category: Avionics
More wire grooming and debugging of tailBeaconX controller. When I upgraded to a new Arduino build, with a new compiler, the original working code broke. Despite cleaning up any obvious compilation errors, there was a subtlety in how variables are handled.

Probably due to my lack of formalism as a programmer, the code would compile and run, but I was getting checksum errors on the serial links due to strange interactions between the serial handler of the two ports. I literally solved this problem in the grey zone between sleep and waking, where my brain is most analytical. Two class instantiations were interfering, and the fix was straight forward.
 
Jun 09, 2022     Installing Resistor Pack - (3.0 hours)       Category: Avionics
Installed a resistor pack that provided series resistors and shunt resistors. These scale down 12V signals and provide a ground path when the signal is disconnected (switch open). This translates the input voltage in a range from 2.5V to 5.0V: 2.5V when the signal is disconnected (switch is open) , and 5.0V when the signal is 15V . With the signal at 10V, (low extreme), the input is at 3.3V. So the right threshold to program is 3.3V.

Using these inputs to monitor switch positions that power the PMAGS and fuel pump.


 
Jun 09, 2022     Wire Grooming - (2 hours) Category: Avionics
More hours tidying up wiring. Getting closer.
Did discover that some of my 'Contact' definitions for the SkyView EMS needs some work. I have switches that are ON or OFF, but in the OFF position, there is no current so the outputs float (and the voltage is undefined). I will check out the EMS definitions file for options (hoping for a pulldown).
 
Jun 06, 2022     Wire Grooming - (2.5 hours)       Category: Avionics
Tidying up wires behind panel.


 
Jun 05, 2022     Trim system integration - (1 hour) Category: Avionics
Confirmed that my custom designed autotrim system is functioning. Panel trim and stick trim buttons working, running the pitch servo.
 
Jun 03, 2022     Trim Integration - (2.0 hours) Category: Avionics
Checking trim system for proper operation.
 
Jun 02, 2022     Completed OnSpeed Integration - (4.5 hours)       Category: Avionics
Swapped audio leads on my mixer to allow attenuation of LOUD OnSpeed audio. Also ran second serial port to all of the huVVer-AVI devices as well as connected all of the X2 inputs to an analog dimmer input.

I will make a PWM to analog buffer to connect to these dimmer inputs.

The second serial inputs are connected to the OnSpeed IMU, this providing a redundant source for air data and attitude.


 
Jun 01, 2022     Integrating OnSpeed - (2.0 hours)       Category: Avionics
Completed the integration and preliminary calibration of the OnSpeed system. Successfully calibrated the IMU and configured the audio levels. Using OnSpeed serial stream to drive the huVVer-AVI display. Successfully tested the dynamic switching of serial ports from the SkyView and OnSpeed.

Also tested a new load of the TailBeaconX control head.


 
May 31, 2022     Rewiring - (3.5 hours) Category: Avionics
Adding connections for second serial ports on huVVer-AVI devices. These will connected to myOnSpeed box as alternate source of attitude and altitude information.
 
May 27, 2022     Device Integration - (5.5 hours)       Category: Avionics
Connected tailBeaconX to tail wiring harness. Downloaded new software into the huVVer-AVI device wired for TBX control. I forgot to remove the serial port jumpers on my MFD connector that were clearly labelled on my schematic, but once they were fixed, I thought everything would work. No joy.

I scoped the serial port on the SkyView and confirmed that data was valid. Turns out that I had a cold solder joint in a device, so that was fixed and I am ready for more testing.

Also removed OnSpeed box for software upgrades.


 
May 24, 2022     Detail Work - (4.0 hours)       Category: Avionics
Fine tuning fuselage wiring. Adding connector shells. Replaced ADSB Antenna coax connector.


 
May 19, 2022     ELT Tray - (2.5 hours)       Category: Avionics
Completed construction of tray, except for priming. Spot primed the overlaps before riveting.

Based on the hours building this tray and the companion ADAHRS tray, it sure would be nice to have premade tray kits from Rans that fit between the bulkheads and can be aligned with the axes of the aircraft.


 
May 17, 2022     ELT Tray - (3.0 hours)       Category: Avionics
More fabrication of the ELT Tray. Added nutplate holes and drilled lightening holes. Checked fit.
Will align the tray to be true to the pitch and roll axis of the aircraft. Not a requirement, but it could double as a second ADAHRS tray if required.

Routed the roughed-in ELT power wires and flat cable to aft of Station 4.


 
May 16, 2022     Wire Grooming and ELT Tray - (4.0 hours)       Category: Avionics
Groomed the prewire for roll trim and control stick wires.

Started fabrication of ELT tray, to be located aft of station 4.


 
May 06, 2022     Completed Flaps Position Sensor - (3.5 hours)       Category: Avionics
Connected sensor to flaps actuator using a DuBro Products threaded pushrod and a clevis from the local R/C airplane hobby shop.

Finished the wiring harness for the flaps sensor and configured and calibrated the EFIS to read the flaps position. The flaps sensor is also connected to the OnSpeed black box, which uses it to calibrate the energy system. Bias voltage (3.3V) is derived from the OnSpeed box, so if it is shut down, the EFIS indicator will not function.

Added a 12V power jack to center console. Console now has two USB 5V, two Barrel 10V (for ANR headsets), and one 12V power source. Didn't put LEMO jacks on this aircraft... have them in my Rocket and never used them.


 
May 04, 2022     Flaps Position Sensor - (3.2 hours)       Category: Avionics
Designing and fabricating a flaps position sensor hardpoint. This will be used with the OnSpeed system for accurate computation of flight energy conditions.

The sensor is a tight fit, and must be located clear of the flap cables. The 4-40 tapped hole locations are also important, so the screw tails don't interfere with the position sensor or flap cables. The sensor is mounted off center so that the slider arm is better aligned with the actuator arm and clears the cables.


 
May 03, 2022     Center Console Wiring - (3 hours)       Category: Avionics
Connected audio circuits and power jacks in center console. Other than second 12V plug, everything completed and test OK. Completed charging port on main battery. Ran pitot heat wiring from panel to fuse.


 
May 02, 2022     Charging Port, ELT Prewire - (2.7 hours) Category: Avionics
Fabricated charging port next to battery. Fabricated breaker support and riveted to battery box using Monel rivets. Wired in 2-wire charging plug.
Ran STP wire for ELT serial/power connection.
 
May 01, 2022     Nav and Strobe Wiring Category: Avionics
Wiring:
Ran shielded wiring for Nav and Strobe lights to aft fuselage from panel tray.

tailBeaconX:
Subsequent test shows that the TBX App is unreliable in connecting to iPhones for configuration. I did manage to connect to an old iPad Mini, though. Since I routinely write code that uses WiFi for data transmission or OTA downloads, I see no excuses here... something that uAvionix should fix!

Hooking my test harness to a serial adapter on my PC, I have successfully passed SL70 altitude and control messages to the TBX. This will allow me to code up a huVVer-AVI controller for transponder control. Dynon's SkyView 'support' for the SL70 protocol only provides altitude information, not squawk codes or mode.
 
Apr 30, 2022     TBX and More Wiring - (3.2 hours)       Category: Avionics
Fabricated a test harness for tailBeaconX and ran landing/taxi light wiring from panel.
The test harness allows for bench top power and connection to a computer serial port. My plan is to implement the full SL70 protocol for control of the TBX from one of my huVVer-AVI instruments.


 
Apr 28, 2022     tailBeaconX Installation - (2.2 hours)       Category: Avionics
Certified TBX installation. Waited a year for delivery!

Now I am committed to designing a control head for the TBX. Using a huVVer-AVI universal instrument, with custom code that takes altitude information from my SkyView system, adds in control information (settable squawk code and mode information) and sends it to the TBX.


 
Apr 27, 2022     OAT Probe Installation - (3 hours)       Category: Avionics
Installed OAT probe under the right side elevator. Ran the wires in braided sleeving for protection. Used 12 gauge Romex as a fish-wire.


 
Apr 25, 2022     Trim controller - (1.0 hour) Category: Avionics
Machining case for own-design trim controller.
 
Apr 20, 2022     Installed trim controller - (3.0 hours) Category: Avionics
Installed custom designed autotrim controller based on the one I made for my Harmon Rocket.
 
Apr 18, 2022     Installed Avionics - (2 hours) Category: Avionics
Installed avionics and fired up panel, plus more wiring.
 
Apr 13, 2022     USB Power Port - (3.7 hours)       Category: Avionics
Ran several more avionics wires and fabricated a circuit board for the USB power port. Secured a 5V regulator to panel tray and connected circuit board and modifed USB cable to panel.


 
Apr 12, 2022     Wiring USB power - (2.2 hours)       Category: Avionics
Mounted 5V power bock and ran twisted pair power connection. Made twisted pair to reduce EMI from the switching regulator.


 
Apr 09, 2022     Wiring - (2.5 hours) Category: Avionics
Continued running wires and marking up schematic.
 
Apr 08, 2022     Wiring - (2.0 hours) Category: Avionics
Completed running EMS wires FWF. Ran roll trim wiring to fuselage.
 
Apr 06, 2022     Wiring EMS - (3.0 hours) Category: Avionics
Running engine sensor wires FWF and status monitoring to panel and fuselage. Specifically, monitoring ignition power is a priority.
 
Apr 05, 2022     Wiring revisions - (2.0 hours) Category: Avionics
More wiring revisions.
 
Apr 04, 2022     Wiring - (3.0 hours) Category: Avionics
Continued with wiring revisions
 
Apr 03, 2022     Updating panel design. - (3.0 hours) Category: Avionics
Rewiring PMAG switches to allow mag power testing without breaker pulling. This was done by replacing single pole with double pole switches.
 
Feb 26, 2022     New Attitude       Category: Avionics
Updated the Attitude Indicator code for my backup instruments. New features include improved graphics and (selectable) recovery arrows that indicate the direction to push or pull to recover from extreme pitch excursions.

Also included are +/- 90 degree markers, just in case, for precision aerobatics.

Note that the pitch numbers on the ‘wing' are filtered and do not represent instantaneous pitch.


 
Jan 25, 2022     New Audio MIxer products coming soon       Category: Avionics
I have spent a few weeks redesigning the audio mixers that I developed 15 years ago. Besides converting to surface mount technology (SMT), I've improved their application flexibility by allowing them to drive headsets directly, if needed. This was all driven by a request from the OnSpeed team to simplify the retrofit of the OS system in existing aircraft with mono audio systems, or those using intercoms where stereo music is muted during com activity.
See installation manual attached. The new mixer(s) will be made available through MakerPlane.

The new design is called the AMX-10A. It has ten inputs, configured as two mono and four stereo pairs. Two of the stereo pairs have individual left and right volume controls, while the other pairs and the mono inputs are fixed level. I will be building a prototype run and have a few on hand for development, while the rest are going to OnSpeed to support their fleet installations. Production will be available from MakerPlane.


 
Oct 28, 2021     Adding connector shells - (1.5 hours) Category: Avionics
Added connector shells where required and groomed wiring.
 
Oct 24, 2021     Stick Grip Wiring - (2 hours)       Category: Avionics
Roughed in stick grip wiring. Left flying leads for pitch trim motor, Current plan is to fabricate an RV-14-like trim motor assembly and attach to cross-tube with springs. This will be connected into my own auto-trim system and eventually become a heading-hold autopilot system that may replace the heavy Dynon roll and pitch servos.


 
Oct 23, 2021     Stick Wiring - (3 hours) Category: Avionics
Rigged control stick grip. I'm using a hat switch, starter switch, autopilot switch and PTT. I plan on two-axis trim.
 
Oct 22, 2021     Wiring center console power jacks - (2.5 hours) Category: Avionics
Power jacks wired and console holes drilled to final size. Added key switch to console.
 
Oct 21, 2021     Wiring headset jacks - (3 hours)       Category: Avionics
Wired headset jacks and completed testing. Wiring also supports power jacks for ANR headsets.


 
Oct 21, 2021     Headset Wiring - (3 hours)       Category: Avionics
Fabricated wiring harness for headsets and trimmed flap lever housing to size.


 
Oct 19, 2021     Audio Wiring - (2 hours) Category: Avionics
Running headset wires.
 
Oct 07, 2021     Fuselage Wiring - (2.5 hours)       Category: Avionics
Connected fuselage grounds and accessory wiring. There are several pieces of equipment that can be grounded locally rather than running to the main panel ground distribution. Since I had an extra ground bus bar in my inventory, it was perfect for this purpose.


 
Oct 05, 2021     ADAHRS TRay - (2.5 hours)       Category: Avionics
Riveted ADAHRS/OnSpeed tray in place, connected and groomed wires. Checked EFIS attitude, looks good.
The units are mounted on 6-32 stainless screws that have been attached to the underlying structure with nylock nuts, forming a 3/4" high stud. Onto these studs, the units can be leveled with washers to fine tune the pitch and roll attitudes.


 
Oct 04, 2021     Assembling ADAHRS tray, attaching comm antenna double. - (1.5 hours) Category: Avionics
Riveted stiffeners to ADAHRS tray and attached screws to secure Dynon and OnSpeed units. Riveted comm antenna doubler to fuselage..
 
Oct 02, 2021     It's Alive - (3.5 hours)       Category: Avionics
Finished rouging in ADAHRS system and comm antenna. Fired up panel and no smoke!


 
Oct 01, 2021     Antennas and ADAHRS - (5.5 hours)       Category: Avionics
Partially installed antennae and mounted ADARHS and OnSpeed boxes.


 
Sep 29, 2021     ADAHRS/ONSPEED - (4.2 hours) Category: Avionics
Fabricating wiring harnesses for ADAHRS and OnSpeed box. Fabricating attachment brackets for OS box. Routing Servo Power and CWS signal.
 
Sep 28, 2021     Fuselage Wiring - (4.0 hours) Category: Avionics
Completed sixth huVVer-AVI and began wiring six-pack. Fabricated extension cable for OnSpeed controller.
 
Sep 27, 2021     Instruments and Fuse Wiring - (3.5 hours)       Category: Avionics
Built up six huVVer-AVI instruments and mounted five on the panel. Ran network cables to aft fuselage.


 
Sep 23, 2021     Aitopilot Wiring - (2.0 hours)       Category: Avionics
Fabricated servo wiring harness. Connected servos to my AXIS-9A hub. This hub design was adopted by Dynon several years ago.


 
Jun 27, 2021     Pitch Servo - (4.5 hours)       Category: Avionics
Rough-in of pitch servo. Used nutplates for servo bracket mount. This simplifies installation.


 
Jun 25, 2021     Roll Servo - (5.0 hours)       Category: Avionics
Installed roll servo for autopilot. Needed to R&R several times to adjust fit. Trimmed tray and flange to improve clearance to cables.


 
Jun 13, 2021     Cutting subpanel for six-pack - (3.0 hours)       Category: Avionics
Used my instrument punch to fabricated a subpanel that will hold an array of my huVVer-AVI instruments.

The instruments are all powered up and connected by WiFi to display ADAHRS data. Picture shows data sent by my computer over a WiFi hotspot using UDP.


 
Jun 02, 2021     Wiring - (2.0 hours) Category: Avionics
Ran fuel pump wires and bundled wires running to aft fuse. Inverted starter contactor to be more G insensitive. Purchased ANL fuse and fuseholder, will mount on firewall.

The additional weight and complexity of the aft mounted master contactor and the ANL fuse is justified by the increase in safety. It is consistent with the wiring on the Vans RV series of aircraft.
 
May 28, 2021     Battery Install - (3.5 hours)       Category: Avionics
Completed alignment of ADAHRS/ELT tray and installed battery box.

Used UHMW anti-chafe tape under the tube clamps. Also used white heat-shrink tubing to insulate the battery retainer bar, in case it rolls free and shorts the battery! I also added washers under the cotter pins to prevent galling of the battery box. I do this in many places where a free-range cotter pin is used. It can also help tighten up a connection so it doesn't vibrate.


 
May 27, 2021     Working on ADAHRS and ELT tray - (3 hours) Category: Avionics
Continued fabricating tray for ADAHRS units and ELT.
 
May 26, 2021     ADAHRS and ELT tray. - (2.0 hours)       Category: Avionics
Fabricating tray behind S4 closeout panel. Tray needs to be aligned carefully for ADAHRS accuracy. Pretty tricky operation and I am assuming that I may need to fine tune the ADAHRS mount once installed.

I put the tray in the S4-S5 compartment because it is easy to access by removing the S4 closeout. I will modify my wooden floorboards for use with the aluminum aft baggage compartment floor still installed. I am uncomfortable putting the ADAHRS underneath the baggage floor because ferrous cargo (such as a bicycle) could affect the magnetometer.


 
Apr 09, 2021     Transponder Prewire - (1.5 hours)       Category: Avionics
Strung new wires to tail for tailBeaconX installation. I upgraded from 22AWG power wiring to 20AWG to allow for a long ground return wire.

Also, production versions of my instrument cases have arrived. The picture shows the 3" version, with new buttons.


 
Apr 04, 2021     Released new Avionics to manufacturing - (.1 hour)       Category: Avionics
Finished a two year project to develop a new family of low cost aircraft instrument.

Mounted one to glareshield of my Rocket for more flight testing. Will put seven of them in my S-21.

Stay tuned for official announcements.

Here is a video: http://huvver.tech/downloads/huVVer-AVI-2_Sunlight.mp4


 
Mar 04, 2021     New Instruments       Category: Avionics
Here's photos of the new family of open-source avionic displays I've developed. They take serial or WiFi info from Dynon or Garmin EFIS systems and displays it in a user-customizable way.


 


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