Jul 06, 2023     Thermal Barrier - (2.0 hours)       Category: Firewall

Ron came over and helped complete the thermal barrier project as we worked on the interior of the cowl duct. It went much easier than expected and a quick test showed the door operated without interference from the thermal material.

  Jul 02, 2023     Parts Assembly - (2.5 hours)       Category: Firewall

After more thermal shield trimming to allow firm seating of the engine mount, it was installed and torqued. Thanks again to Dean and Paul for their help. For the most part it went as planned. Only one battery cable needed to be removed. It'll be easy to put back in place later.

  Jul 01, 2023     Parts Assembly - (5.0 hours)       Category: Firewall

Finished a few odds and ends on the firewall thermal panels then I began to assemble parts onto the firewall before the engine mount goes on thinking that would be easier. It's a little out of sequence so I hope this works out. In doing the master and battery solenoids here's a caution. When attaching the diode on the battery solenoid, note that that the length of the wire is just right - with no slack. Thus, you have to be really careful how you attach it to the mounting lug and the upper terminal, it's a tight fit. Also, I found the copper bar holes were too far apart and did not fit well. I had to bend it and enlarge the holes to get it to fit. I'm pretty sure it'll be okay. Everything else was straight forward.

  Jun 30, 2023     Thermal Barrier - (4.0 hours)       Category: Firewall

I completed the left side firewall thermal barrier and then glued all 3 pieces in place. I left the bottom center unattached for the moment as this will extend into the cowl flap which I'll get to once the plane is on it's gear. Small strips of aluminum tape were placed along some the seams and around some of the holes. More will be added soon to give it a good seal. Overall I think it came out okay. The thermal material is certainly hard to cut. The backside of the aluminum is the barrier with the glue side against the firewall. This is the same material used on NASCAR's. (It helps to live in the Daytona area.)

  Jun 29, 2023     Thermal Barrier - (2.5 hours)       Category: Firewall

On the upper thermal barrier I had to locate and cut the two holes which support the manifold pressure module. Using the template I cut the lower portion of the right side thermal barrier and did the usual fit check. It fits!

  Jun 27, 2023     Thermal Barrier - (3.0 hours)       Category: Firewall

With the templates completed I also installed the fittings on the oil and fuel pressure manifold. I decided to cut the upper portion of both the left and right thermal barriers as one piece to make the installation a bit easier - I hope. So, I laid out the cut patterns on the thermal barrier and made the upper portion cut. I test fit the manifold with the thermal barrier temporaily installed and it's good.

  Jun 26, 2023     Thermal Barrier - (2.0 hours)       Category: Firewall

I finished the left side template and also completed the right side template for the firewall thermal barrier.

  Jun 25, 2023     Thermal Barrier - (2.0 hours)       Category: Firewall

I am going to install a thermal barrier on the forward side of the firewall. To do this I'll need to have a roughed out template that can provide approximate sizing around screw hoes and the various fittings installed on the firewall. I took a large piece of cardboard and began the process of cutting holes in it so it would lie flat on the firewall. I managed to get about 60% of the left side template completed this afternoon. Once I'm fully satisfied with the fit I'll cut the thermal shield, per the template, leaving some extra material to allow for my in-precise template measurements.

  Jun 19, 2023     Parts Assembly - (1.0 hour)       Category: Firewall

I enlarged the hole slightly I drilled yesterday for the spherical grommet. Then I spread high temp RTV around the backside of the grommet, inserted it into the hole and with Dean on the inside, we installed the backplate. Once that was done, I loosely installed the spherical insert and the plate that holds in place.

  Jun 17, 2023     Parts Assembly - (1.0 hour)       Category: Firewall

I removed the fuselage rotating attach hardware and stored it for the future. Using the template on OP62-03 I drilled thru the firewall in preparation for the installation of the CT-102 double spherical grommet. Drilling thru the stainless steel took quite some time and although the holes don't look symmetrical they fit the CT-102 perfectly.

  Jun 18, 2022     Inventory - (2.0 hours) Category: Firewall

I completed the parts inventory today and noted that a few items were missing. I called Van's and they said they would immediately correct everything. I expect the missing parts to be here within a week. Not a problem as there's still quite a bit left to do.

  Jun 16, 2022     Firewall Forward Inventory - (3.0 hours) Category: Firewall

I received my Firewall Forward Kit on June 14 and started the inventory on the 16th. Only one box (of three) arrived so it's no surprise that a substantial number of parts are on backorder parts. It's not Van's fault and it's not a big deal as Van's and I have adjusted to the new way life. I know Van's is doing the best they can given the circumstances in today's reality.