Jun 28, 2023     Baffles - (4.0 hours)       Category: Firewall

Fabricated an insert to ensure a smooth transition for the aft baffle seal. Based on something similar developed by Vans Aircraft. Used my trust box & pan bending brake and some scrap left over from a shipment-damaged baffle.

  Jun 27, 2023     Baffles - (3.3 hours)       Category: Firewall

Riveting baffle supports in intake nostrils. Going off the trail a bit, but I decided to line up baffles more with the shape of the nostrils.

  Jun 26, 2023     Cowl Fitting - (4.0 hours)       Category: Firewall

Finished the fitting of the cowling, although some minor sanding and filing is required for paint prep. Updrilled to #30 clecoes. Trimmed cowl exit. Discovered that the new Figures for the cowling are different than the ones I used. At some point, Rans' customers are going to rise up and demand proper version control!

  Jun 25, 2023     Cowl Fitting - (2.0 hours) Category: Firewall

More fitting of cowl. Trimmed nostrils to 1.75" depth, and drilled for nostril clecoes #40. Reshaped forward right cowling edge to match up with bottom cowl.

  Jun 24, 2023     Cowl Fitting - (3.5 hours)       Category: Firewall

Drilled and clecoed cowling. Still needs some fine tuning. Removed tape residue and black dust with laquer thinner.

  Jun 23, 2023     Cowl Fitting - (2.5 hours)       Category: Firewall

More trimming and fitting. Clecoed top cowl in place.

  Jun 22, 2023     Cowl Fitting - (3.0 hours)       Category: Firewall

Fine tuning cowling fitup. i have seen others that end up with a bulge in the top cowling on the front left quarter. My solution was to trim a bit more off the back left side.

  Jun 21, 2023     Cowl Fitting - (2.5 hours)       Category: Firewall

Made the big cuts along the sides and back of the top cowl and the back of the lower cowl. Now a lot of fussing to fine tune the fit. I plan on a 1/16" seam gap to allow for paint and reduce fretting.

  Jun 20, 2023     Cowling Fit - (3.0 hours) Category: Firewall

Carefully measuring and fitting cowling. Rans instructions are confusing, so I am winging it, like I did on my Rocket.

  Jun 19, 2023     Cowling - (2.0 hours)       Category: Firewall

Fitting up lower cowling.

  Jun 17, 2023     Brake Filling - (1.5 hours) Category: Firewall

Filled L&R brake systems using pressure pot. Pumped brakes during fill to ensure master cylinders had no air bubbles.

  Jun 16, 2023     Cowl Fit and Brakes - (3.0 hours)       Category: Firewall

Marked lower cowl for trimming. Preparing for adding brake fluid to the system. Want to do this while the boot cowl is still removable, in the event of a leak that needs repair.

  Jun 15, 2023     3.0 Category: Firewall

Clecoed boot cowl sides and bottom in place, and used temporary rivets around th firewall to allow the lower cowling to be fit. This way, I can still access the interior and avionics later, yet proceed with cowl fit up.

  Nov 16, 2022     Coanda Exit Fairing - (1 hour) Category: Firewall

Trimmed exit fairing and remounted to firewall. Clecoed bottom forward skin in place to line up holes with firewall flange and exit fairing, ready for match drilling. Once drilled, the exit fairing will be remounted to overlap rather than underlapped the bottom skin.

  Nov 15, 2022     Coanda Exit Fairing - (3.2 hours)       Category: Firewall

Continued fabrication of the Coanda exit fairing. Drilled for attachment rivets and fabricated brake reservoir line cover. The top row of rivets will be stainless, as a fire block. The bottom row can be aluminum, because they do not penetrate into the aircraft interior.

The exception is that the line cover will be attached with 4-40 stainless screws, to allow for maintenance.

"The Coanda effect is the tendency of a fluid jet to stay attached to a convex surface".
https://www.thermopedia.com/content/5060/166CEFig1.gif

  Oct 28, 2021     Wired Shunt - (3.2 hours)       Category: Firewall

Attached the shunt to firewall, connected to ANL fuse with a copper busbar and ran master bus cable through firewall to panel. White Romex in photo is my temporary power connection to the panel. This combination of devices on the firewall is non-standard: The master contactor is next to the battery in the forward baggage area, the ANL is my own choice and the starter contactor is mounted upside-down to prevent inadvertent operation with high G loads.

The fuse is the stock Dynon provide unit--- not my favorite device because of the plastic body. The one in my Harmon Rocket melted and I had to make a phenolic base for it. I will keep my eye on this installation in the S-21

Also, rerouted cable bundle in fuselage to prevent interference with seat.

  Oct 17, 2021     Attaching ANL Fuse - (3 hours)       Category: Firewall

Attached ANL fuse holder, bent and drilled copper busbar to attach to start solenoid.

  Apr 01, 2021     Firewall attachments - (5.0 hours)       Category: Firewall

Dave W. 2.5 hrs. Fitting oil cooler, starter solenoid and gascolator mount to firewall. Applied a small bead of high-temp RTV to gascolator flange to help seal against CO leakage.

  Mar 24, 2021     Marking firewall - (3 hours) Category: Firewall

Dave W. Laying out firewall for accessory mounting.