Sep 23, 2022     Power Budget - (10 hours)       Category: Instrument Panel

Sonex was designed with a 20 Amp alternator. By adding Electronic Fuel Injection, Electronic Ignition, and Installing a full IFR panel, A significant increase in power consumption is realized. In order to tally these power loads, I have created a spreadsheet. As I acquire these devices and bench test them--I will have more accurate power calculations.

  Sep 19, 2022     Return after learning a lot - (4 hours) Category: Instrument Panel

I took a long break from working on the Sonex. In that time I obtained my IFR rating and Complex endorsement. More importantly, I've been working for Texas Aircraft and Bario Aviation doing avionics repair / installation and simulator reverse engineering / repair. Certainly discovering better ways of approaching electrical system design and redundancy; specifically while troubleshooting the Colt 100 aircraft with full Garmin glass panel. The Colt 100 utilizes a LiFe backup system for the avionics in addition to 2 alternators and main battery. I will apply what I've learned there as well as from the Aeroelec connection book (free online) and other texts that I've gleaned information from.

  May 06, 2021     Top Level Panel Interconnect - (10 hours)       Category: Fuel System

After adding the second EFIS, I wanted to make sure I had the ability to connect all devices and cross connect the PFD and MFD for redundancy. I produced a top level diagram with brief connection info to the equipment I am installing.

  May 01, 2021     Panel Redesign and more thoughts - (10 hours)       Category: Fuel System

I believe I am narrowing down this build.

I wanted light IFR capability and autopilot which necessitated adding more avionics. I added a total of 2 GRT Sport EX EFIS's, the Garmin GNC 355 GPS/COM, Garmin SL30 NAV/COM, Garmin GMA 245 Audio, SDS EFI Aero Programmer, and required switches to facilitate full electronic engine control. This created three issues:

1. I needed a larger panel to fit the avionics displays and it would have to be vertical instead of angled.
I can make the panel larger (about 1.5" taller), mount it vertically, and round out the top of the panel (like the sonex-B model).
2. I needed a bigger alternator to power all this stuff.
My calculations show that I should use the B&C 40 Amp alternator and remove the standard alternator from the AeroVee. I will have to fabricate a V-belt crank pulley on my lathe and cnc machine.
3. Even with a larger and vertical panel, the SL30 nav/com will not fit with the standard sonex fuel tank.
I believe I can fabricate a carbon fiber fuel tank and glare shield with a 2" notch in the back to accommodate the nav/com stack and also take space now available due to the new glar shield following the instrument panel curve. Additionally, I can extend the tank left and right around the nav/com stack to increase the tank size to 20-22 gallons.

  Mar 24, 2021     SDS EFI - (8 hours) Category: Fuel System

I want to put EFI and ignition control on this aircraft. I have been thinking about it for a while, then listen to the sonex aviation podcast episode 58 which spoke about this system.
I have spoken to SDS (twice) about their EM-5 4F electronic fuel injection and ignition control for my aircraft. I have decided to pull the trigger. I have order the following from SDS:

EM-5 4F Engine Control Unit (ECU)
65mm Throttle body
Dual Pump bracket

The ECU has been order to have both ignition control and per cylinder fuel injection tuning. I purchased the following parts locally:

2x Walbro GSL393 155lph fuel pumps
4x Edelbrock 3574 EV-14 Fuel Injectors
1x Holley MAP sensor for Turbo applications
2x Standard Motor Ignition coils UF240T
1x 100 micron Holley billet fuel filter
1x 10 micron Holley billet fuel filter
1x Holley adjustable billet by-pass regulator- 6AN
2' of aluminum extruded Fuel rail
2' of aluminum tubing for injector bungs
1x TPS potentiometer

I will purchase the remaining AN-6 fuel hoses and fire sleeve once I have the injectors installed to get a proper measurement.

  Dec 02, 2020     More Panel Research and some decisions - (6 hours)       Category: Avionics

In a light IFR panel redundancy is on my mind. I kicked around getting a Uavionix AV-20-S for redundant AI and realized I was not redundant in Nav sources. I checked with GRT Avionics (manufacturer of the EFIS I possess) and decided it would be better to put in an identical GRT Sport EX EFIS (to support vertical autopilot guidance) as well as the Garmin SL30 NAV/COM.

With this set up, I have redundant AI, HSI, two IFR Nav sources (GPS and NAV radio), and two COM radios. The next big problem to tackle is the Sonex AeroVee's anemic alternator power output of 20 Amps. This aircraft was not originally designed for IFR or (probably) VFR night flying. The panel isn't large enough for a decent IFR layout... and the power output is way under what I would consider a safe margin.

The AeroVee engine is a standard VW horizontal aircooled engine. Great Plains aviation makes a different accessory plate by Diehl that has a 35 Amp alternator. This is a vast improvement in power output. I will attempt to do a drop in replacement for the stator and possibly flywheel... upgrading to a three phase stator and voltage regulator.... but I can always fall back on the Diehl accessory plate if that doesn't pan out.

  Nov 12, 2020     Update Panel Wiring Schematics - (3 hours)       Category: Avionics

Contacted GRT Avionics technical support to discuss connections to the GRT EFIS... adding an ARINC429 adapter to interface with the Garmin GNC355. The GRT Sport EX has dedicated connections for a digital Magnetometer that I intend to mount in the wing as well as a dedicated connection to the Trig TT22 Transponder. The Sport EX in addition has 6 serial connections available. I am connecting Serial 1 to the Roll/Pitch Servos on the Autopilot, Serial 2 is connected to the ARINC429 adapter to the Garmin GNC 355, Serial 3 is connected to the Stratux ADS-B In, and finally Serial 4 is connected to the GRT EIS module.

These connections are depicted in the wiring diagram (created in EasyEDA; a free program).

  Nov 10, 2020     Planning panel upgrades - (8 hours)       Category: Avionics

In order to support my training and mission of the sonex, I have purchased a Garmin GNC 355 and Garmin GMA 245. I am considering the SDS fuel injection system for the Turbo AeroVee. I believe I will have to rewind / replace the stator in the AeroVee alternator (rated for 20 amps) to increase power output to support IFR, autopilot, and fuel injection. Thankfully, planning is free.

  Sep 10, 2020     Purchased partially complete Waiex A - (6 hours) Category: Inspection

The previous owner gave me a tour of the partially completed air frame covering parts that were done as well as not done. Big items to complete: L and R wings are not assembled or skinned, Flaps and ailerons need to be completed, engine is not fully assembled, avionics are not fully wired (though the panel is looking good), interior incomplete.

It took most of a day to load up the parts into the moving truck and in our haste to make the 3.5 hour drive back, we forgot a box of wing ribs and sheets of aluminum.