Oct 16, 2018     FiberFrax fitting - (2.00 hours)       Category: Firewall Forward

I used the Titanium sheets to trim the FiberFrax and also marked the holes. I then used punches to�ke the holes. It only required slight hand pressure to push through the material.



The large holes were cut out using a sharp knife.

  Oct 06, 2018     Eyeball fitting - (1.00 hour)       Category: Firewall Forward

Used a hole puncher to enlarge the hole for the eyeball and test fitted the hardware.

  Oct 06, 2018     FW Titanium sheet - (2.00 hours)       Category: Firewall Forward

I used the paper template and trimmed the Titanium sheets to fit the FW. I taped the sheet to the FW and with slight pressure, used a drill and started to transpose the holes from the FW to the Titanium sheets. I enlarged the control cable center hole so I can fit a hole puncher for the large hole where the eye goes.

  Oct 03, 2018     Firewall clamps - (1.00 hour)       Category: Firewall Forward

There are a few places that require clamps for various hoses, these will need nutplates. All of them are marked on the OP-27 drawing.

  Sep 30, 2018     Prepping for FW insulation - (3.00 hours)       Category: Firewall Forward

I decided to make a template for the Fiberfrax and the Titanium sheet I plan to use. First I removed all the parts I had fitted.
Then I used thick paper to trace out the shape of the FW.
I also decided to move the fuel line stiffener from the hot side to the inside of the cabin.
I custom made it so that it can be riveted to the FW angles hence it will probably be stronger than the original Van's design.

  Sep 29, 2018     Firewall stifferners - (2.00 hours)       Category: Firewall Forward

The various FW mounted parts requires stiffeners. I had drilled most of them when I fitted the parts so I only had to deburr and prime.

  Sep 22, 2018     Control Cable Penetrations - (1.00 hour)       Category: Firewall Forward

Positioned and drilled the control cable penetrations using a steel template. I don't have the eyeball harrdware yet, so the big central hole have to wait.

  Sep 16, 2018     Oil separator and forest of tabs - (1.00 hour)       Category: Firewall Forward

Instead of getting oil on the belly, I decided to get the oil separator from Antisplataero. I had to research a little as I though it would interfere with the oil filter, but it is far away from that.
I also positioned and drilled the forest of tabs to the firewall.

  Sep 15, 2018     ANL fitting - (2.00 hours)       Category: Firewall Forward

I will have two ANL fuses, one for each alternator. I got some ANL holders from B&C and manufactured some 1/8" copper strips to provide connection to the master relay. I bent them a little as the relay output is nearly in the same plane as the ANL connection bolts.

  Sep 14, 2018     Cable penetrations - (1.50 hours)       Category: Firewall Forward

I punched out two cable penetration for the wiring and dry fit the stainless steel hardware.

  Sep 12, 2018     Firewall Insulation - (1.00 hour)       Category: Firewall Forward

I would like to add FW insulation as it will reduce the heat transfer into the cabin all the time and also provide some added fire protection.
The VAF website have several threads both describing and discussion the topic.
I will use FiberFrax and Titanium sheet which will provide a nice flat surface.

  Sep 11, 2018     Battery case - (1.00 hour)       Category: Firewall Forward

I got my EarthX battery case today. It uses the same hole pattern as Van's version and also can fit all possible batteries.

  Jul 05, 2018     Oil cooler mounting option - (0.50 hour)       Category: Firewall Forward

Got the oil cooler install kit from https://showplanes.com/ecom-prodshow/OCM-7.html. This allows the cooler to hang on the engine mount rather than the baffles.
It requires 13 rows cooler, I thought I could make it fit a 9 rows, but then I decided to go for a 2006x which would fit.

  Jun 17, 2017     Red Cube - (0.50 hour)       Category: Firewall Forward

Got the Red Cube from Aircraft Spruce.

  Feb 05, 2017     Fuel line and parking brake doublers - (1.50 hours)       Category: Firewall Forward

Manufactured the fuel line and parking brake doublers. The fuel line doubler is overlapping a firewall stiffener and will therefore be on the flat (engine) side. Van's still specify aluminum, something I did not like. I got a galvanized plate from the electrical department at Home Depot instead. The parking brake doubler is straight forward, I used countersunk screws to have a smooth firewall.

  Dec 21, 2016     Brake fluid reservoir - (0.50 hour) Category: Firewall Forward

Deburred the brake fluid reservoir as this will be anodized as well together with the pedals.

  Oct 03, 2016     Firewall components - (2.00 hours)       Category: Firewall Forward

Continued the starter and master relays nutplates. Two goes through the Firewall stiffener, the two other require additional stiffener plate. The stiffener also serves a template for the firewall drilling.

  Oct 02, 2016     Firewall components - (1.50 hours)       Category: Firewall Forward

Measured and started drilling nutplates for the starter and master relays. One rivet is removed and used for positioning, then the two remaining is determined by the nutplate.

  Sep 30, 2016     Firewall components - (1.00 hour)       Category: Firewall Forward

Got the first firewall forward parts. Master and Starter relays and a Grove parking brake valve.