Jan 31, 2024     Gone Fishing - (4 hours) Category: Instrument Panel

Drilled new holes in BH A for the 2nd main battery cable going to the aft battery placement. And another 3/4 inch hole for the ACK ELT cables and the horizontal stab trim motor cables. Ahhh...then realized I'd have to imitate a hot dog in the bun to get into the fuselage tail sections for BH B, C, etc to run the cable back to the trim. Instead, went fishing...as in using a variety of wires and strings to feed the cabling remotely through the other bulkheads. This of course after realizing that the other BH holes drilled long ago were too small for the cable already pinned into a molex connector to pass through. Thankfully had the molex pin removal tool from back in my Sportsman days. Unpinned, ran the cable, repinned. Time consuming but easy-peasey.

  Jan 30, 2024     Reviewing - (2.3 hours) Category: Instrument Panel

Running cables back to the tail requires drilling new/addtional holes in Bulkhead A. Reviewed all manuals and TWTT photos for input on which setup to use. Also, realized I'd better trial fit the Autopilot tray that sits under the seats to be certain I've got clearances for the various cabling crossing the area....A-OK. Will drill in BH A tomorrow.

  Jan 29, 2024     Getting wired - (4.15 hours) Category: Instrument Panel

Progresss on the power cables; crimped the positive battery cable end and then bolted to the master cylinder.
Spent much time actually running the wiring cables; fun to thread the various cables under/over the cage pipes, zip ties to be sure wiring not too close to the control cables, and so on. Also ran the long cable that controls the elevator trim servo, and was relieved to find it was not too short. Making progress.

  Jan 24, 2024     Mounted and wired MAP - (2.25 hours)       Category: Instrument Panel

Gingerly got under panel and mounted the MAP hose to firewall, then spent a very frustrating time twisting to put in an Adel clamp to Adel clamp on the right forward side of the cage. Then wired into the system with red butt clamps. whew. Did use some shrink wrap over the butt connections for protection.

Moved back forward of the FW and started redoing the mag blast cooling hoses' position...which have been pointed out as not being aimed correctly. Will finish repositioning tomorrow.

  Jan 23, 2024     Redid MAP hose - (1.8 hours) Category: Instrument Panel

Was not certain that one end of the MAP hose was secured well enough (as in leak free). Redid the clamptite wrap with the .032 safety wire.
Worked at bench, as still too restricted to work under panel, after a trip to Mayo late last week.

  Jan 17, 2024     MAP connection aft of the firewall - (2.6 hours)       Category: Instrument Panel

Final sequence figured out for the MPA aft of the firewall and then fabricated. Used a new tool (Airventure 2023) called the clamptite to wire the AN fittings to the rubber hose.

In sequence from the firewall: bulkhead fitting AN832-3D, AN980-D616 washer, AN924 nut to fabricated hose on flared 3/16th tube with AN819-3D sleeve, 818-3D coupling nut to 1/4 inch ID/1/2 inch OD rubber hose and then the same tube AN819 and AN819 on the other end of the hose to an AN816-3D nipple, to AN910-1D coupling to the MAP probe itself. Used a double wrap clamptite of .032 on both hose over tube ends.

Spent way too much time on this connection. Oh well. Might have been a simpler way, but was definitely scrounging to use the bottom of my parts on hand.

  Jan 16, 2024     Trying to finish plumbing up the probes and power to the panel - (3.1 hours) Category: Instrument Panel

Decided how to plumb the MAP line through the firewall. Brief trip to Wipaire for parts. Decided to pause on the MAP install and jump over to the main battery cable positive from the rear. This required removal of the forward tunnel covers, which wil also let me get at wiring the booster pump. Did the final crimp of an Oring terminal to the positive battery cable. Then also finished the ring terminal crimp and bolting of the main battery negative to the aft cage.

  Jan 12, 2024     The sniffles - (1.5 hours)       Category: Instrument Panel

Added firesleeve to the sniffle valve stem/hose, and adel clamped so that it would drain inboard of the gascolator.

  Jan 11, 2024     Stop dithering - (2.15 hours) Category: Instrument Panel

Well, realized I'm spending too much time proof-reading the Glasair documentation on trivial issues. Reread the sniffle-valve steps and detailed my on-hand inventory of AN fitting pieces. Time to restart building!

  Jan 10, 2024     Frustrating - (.1 hour) Category: Instrument Panel

Total waste of time. TWTT 4000 has a typo/ommission regarding the MAP probe in the cockpit. Spent several hours looking/reviewing the Glasair documentation, the owners' site postings, and all my TWTT step pages. Also spent a crazy amount of time searching the plastic boxes for parts and referring to option picking lists. Put a token .1 hour in for the entry on the log. No joy, no solution yet. Thankfully it's an easy point to resolve if I simply accept that Glasair screwed up, and just do my own best practice which I will do tomorrow.

  Jan 08, 2024     Looong Ratchet - (3.5 hours)       Category: Instrument Panel

Finally had success getting the adel clamp to sump bolt in place; "built" an extra long ratchet using all my extensions and was able to reach the bolt in from the top of the engine. Took almost 2 hours off for EAA committee meetings. Then finished fabricating the cable from starter to starter-solenoid. Cleaned up the wiring clusters FWF on right side, and then aft of Firewall on left side.

  Jan 06, 2024     Starter and also Adel-difficulty - (2.9 hours)       Category: Instrument Panel

Started the day re-reading the Emag installation notes. Then moved to finishing the wire fabrication for the starter motor connection. Got to use my new toy again...a hydraulic crimper from HF. Completed the connection, and then also cleaned up/adel clamps for the left side of the FWF.

Moved over to cylinders 1 and 3 for securing wiring bundles, but spent a crazy amount of time (unsuccessfully) trying to get the bolt into a previously installed adel clamp under #3. I waited to do so until all the wires routing forward were in place, but now very difficult to get at it. Will try again next week, hope I don't have to start taking things apart to get at it and finally get it in place.

  Jan 05, 2024     Shunt - (3.75 hours)       Category: Instrument Panel

Untangled document confusion over the amperage shunt connections to alternator B lead, the circuit breaker, jumper to the battery contacter, and the shunt instrumentation. Aerotronics was instantly helpful...they not only have schematics on each job, but also plenty of pictures of "actual as built". Completed the alternator power and field wiring.

Started on the starter wiring; cut to length and stripped. Crimp the 5/16th ring terminal tomorrow.

  Jan 04, 2024     Grinding forward on the FWF wiring - (3 hours) Category: Instrument Panel

Good light in the afternoon, so managed to complete the alternator field wiring.
Then moved on to the alternator's output wire...awg #8 so I got to use my new toy...a pneumatic crimper for larger wires. Completed the forward ring crimp with shrink tube. Ran the wiring through passthrough A and up to the right side accessory plate to the shunt connections.

  Jan 03, 2024     FWF wiring progressing slowly - (5 hours) Category: Instrument Panel

Started wiring the engine oil temperature probe, but got distracted as I noticed an aft engine fitting still with a red plastic cap. Did not ring a bell. Lycoming manual 72-60 page 39 calls it out as a crankcase vent fitting. Also nearby, the tach RPM drive hole is capped; unclear if it was a simple "shipping" cap, or a permanent steel cap. Spoke to Lycoming tech service, who confirmed it's the steel cap (magnetic) and "good to go permanently" as is. Also finally found a photo of the crankcase vent hose on TWTT 039-0460-80 for Baffling (?), and also a hose in the TWTT 4000 steps.

Finished wiring the oil temp sensor, and then worked on wiring the alternator field wire; ran out of light/got too dark = finish the splice tomorrow.

  Dec 30, 2023     Wired 1/3 egt/cht and red cube - (3.05 hours) Category: Instrument Panel

Completed the EGT and CHT probe wiring (cylinders 1 and 3); then moved on to reviewing and installing the fuel flow transducer wiring. Used the small barrell connectors that came with the red cube, but not convinced they will last. May redo and use butt joint connectors. Decide manana.

  Dec 29, 2023     Traction FWF - (4.65 hours) Category: Instrument Panel

Finally! Got some traction in the front end.....wired in the fuel pressure transponder. Then wired in the oil pressure transponder. Then wired in Cylinder #4's EGT and CHT probes. Then wired in Cylinder #2's EGT and CHT probes. The EAA and Kitplane videos were priceless.

  Dec 28, 2023     Ready to wire! - (0.9 hour) Category: Instrument Panel

Finally clear on which tool/techniques/FWF components to be wired. Unfortunately pulled away by unexpected phone call. Manana.

  Dec 27, 2023     More of the same - (1.05 hours) Category: Instrument Panel

Re-watching how to videos from Stein Air, EAA's Hint for Homebuilders, Aerotronics folllowup. It is slowly coming into focus....whether a circuit needs to be replaceable/removable is a key factor. The sequence as an example for EGT wiring = Route the wires, determine length and where to "fold", actually trimming to length, stripping, crimping, connecting with tiny screws, heat tube shrinking, and overall coverage with the Alcor fiberglass tube. And do this 32 times for egt and cht wiries.

  Dec 26, 2023     Dithering - (2 hours) Category: Instrument Panel

Still quite uncertain about the FWF wiring techniques. Twist/solder, butt joints, solder splices, mechanical crimping, handshakes, and so on. Spent time further studying the tools and methods. TWTT documents are in conflict with older Glasair info....some of it is the prevelance today of Garmin (which is 100% of my panel and plane) contrasted to the previoius dominance of other electronics firms. Studying!

  Dec 22, 2023     Ed for Technique and transducers - (3.1 hours) Category: Instrument Panel

Viewed all the Stein videos, re: cutting/crimping/terminals/molex/d-sub connectors/soldering/ and so on. Also spoke to Aerotronics regarding Manifold Pressure Installation relative to silicon tubing as well as wiring. Insight was that Glasair had designed the MAP to be inside the cabin when Garmin was not prevalent. Now it's a bit of anachronism with the Garmin units and the electronic ignition. This all clarified the emag installation to be done, and the completion of the FWF wiring.

Took a quick drive (not in the hours reported) to Faribault to buy a sub-D crimper from Stein Air.

  Dec 20, 2023     Ready to Terminate - (2.9 hours)       Category: Instrument Panel

Completed the right firewall wiring passthrough "B"; 13 wires (mostly multi-strand) firewall-forward. Required re-reading the P-Mag installation manual and the "red cube" fuel flow transducer installation information. Now ready to start making the bundles "pretty" and trimming almost all wires which came with extra lengths. The actual crimping and terminating should go quickly at this point.

Need to source several #2 gage cables; battery plus to master solenoid, and the starter power wire. May simply outsource the cable fabrication; nominal cost, no real "learning", and I don't have the parts. TBD.

  Dec 19, 2023     Going Backward to go Forward - (2.75 hours) Category: Instrument Panel

The wiring harnesses from Aerotronics are a thing of beauty. Completely obviates the need for the conduits in each wing I so carefully installed a year (?) ago, and I can think of no reason to leave them in place. Removed the conduit from each wing, although I'll leave the metal tabs installed. Then re-ran the wiring harnesses from Aerotronics in the wings.

Partial installation of the alternator, and capped the unused "alternator out" optional alarm.

  Dec 13, 2023     Wiring Technique - (2 hours) Category: Instrument Panel

Review and research of various sources for aircraft wiring. Also spoke with Aerotronics for "best practices"....solder and/or crimping and/or heatsleeve vs heat resistant sleeves in the firewall, and so on.

  Dec 12, 2023     EGT/CHT routing - (1.5 hours) Category: Instrument Panel

Pathed the egt and cht wires from the firewall to the cylinders. Nothing special.

  Dec 11, 2023     Wiring Considerations - (1.65 hours) Category: Instrument Panel

Reviewed the panel documentation and wiring plans.

  Dec 06, 2023     Wiring Fun - (3.55 hours)       Category: Instrument Panel

This really is fun for now. Routing the various wires to the appropriate destination. Boost pump
wiring was not to be found; finally (!) located it in a bundle of wires not opened, and lurking under the accessorty panel. Once I cut the bundle open, sure enough there was the boost pump wiring. This is fun!

  Dec 05, 2023     PITA Bracket for Bulkhead - (3.5 hours)       Category: Instrument Panel

After fabricating the bracket, riveted it to the belly of the plane. This made the install of the connector plugs a real PITA. Spent hours doing so, made more difficult by the likely reversal of the bracket after drilling. The documents showed it multiple ways in error. Did get it done.

  Dec 04, 2023     Bracket for "Bulkhead" - (5.05 hours)       Category: Instrument Panel

Fabricated the bracket which Glasair calls a "bulkhead".

  Dec 01, 2023     Easter in December - (3.85 hours) Category: Instrument Panel

The further I get, the more I search for parts....like an Easter Egg Hunt. Looking for parts from Wing Laydown steps last seen or worked on a year or two ago.
Really fun to find a "missing" part. Returned to TWTT 250 for wing wiring, and had fun laying out the cables. Can't decide whether to remove the conduits I put in place back in 2021, since the actual cabling came ensleeved and not needing the conduit paths. TBD.

  Nov 30, 2023     Spaghetti - (2.75 hours)       Category: Instrument Panel

Routing the cabling. Quite a tangle for the moment. There really is no interconnect schematic; TWTT experience is proving helpful, but there are significant differences.....eg Glastar a 2-seater = no need for wiring to "back 2 seats and headsets" = no need for right fixed bulkhead connection. And so on.

  Nov 29, 2023     Zippety-Do-Dah - (4.45 hours) Category: Instrument Panel

Zip tied the wiring bundles to the cage, center, left, and right sides. Connected the GEA24 (partially), the GMA 245, and the GAD 29.
Interestingly enough I noticed the led on the GEA24 was lit...and I have yet to install the main battery. Realized that the Standby Battery System was live, and that with the mains switch inadvertently "on"....that various system units were getting power! Turned it off before I shorted something out or ran down the battery.

  Nov 27, 2023     Connecting the plugs - (2.95 hours)       Category: Instrument Panel

Sorted hardware leftover in various previously done steps and merged it into my parts' inventory. Then reviewed the wiring twtt 4600, and then started twtt 5300. Sorted out the various plugs and connected the GDL 51R, the GAD 29, the GTR comm #2, and the GMA 245. (all left side). Then connected the GEA24, the TCW Battery Backup System, and the grounds' plug.

  Nov 14, 2023     Patching wires - (3 hours) Category: Instrument Panel

Finally returning to the wires I accidentally cut while trimming off an unused weld tab behind the panel. Spliced the broken wires and soldered.

Then AGAIN replaced the small accessory left panel which came from Aerotronics; this replaces the carbon fiber panel sent in error. Good fit.

  Oct 31, 2023     Finalized left accessory panel - (2.05 hours)       Category: Instrument Panel

Checked and rechecked fitment of the left accy panel.Realized that the top component connectors will be so close to the fuselage as to not being usable. Took apart the top and reversed the COM2 box to better access the connector, which then meant moving the ACK audible alert. Redrilled 3 of the adel clamp holes. While the "pretty parallel lines" of the pre-assembled panel are no longer parallel or pretty, it's functional and the price to pay for having the panel preassembled as a unit.

  Oct 30, 2023     Left Accessory Instrument Panel - (4.15 hours) Category: Instrument Panel

First hour was getting the last 2 adel clamps on the RIGHT accessory panel, which required a redrill (dimension not the same as TWTT).

Then moved over to LEFT instrument accessory panel. Here we go again....this time it's Aerotronics using the Sportsman jig for the build. Sure enough, the Glastar cage pipe interferes with the Garmin 245R connectors. So ok, reverse the 245R to face the outher way...oops the other way is NOT symetrical, and has its "front panel" now interfering with the cage pipe. So take it off and redrill? Sure, except that means taking off the other side instruments (COM2) as they block the 245R's screws.

Basically had to disassemble both sides and 3 instruments to redrill for the one. Reassembled and put in place on the rails, but the Adel clamps do not have room to fit into the predrilled holes. Great. Man'ana!

  Oct 28, 2023     Install of panel accessory sub-panel - (3 hours)       Category: Instrument Panel

Slow going in terms of available hardware. Many hardware items are now zero stock as they've been used. Spent a fair amount of time inventorying/searching for a variety of machine screws. At any rate, ground off the paint from one of the cage tubes, and removed the rubber from two Adel clamps to both mount the right panel as well as create a ground path to frame.

  Oct 27, 2023     Installation of fabricated braces - (4.05 hours) Category: Instrument Panel

Quite the search for mounting hardware; nothing unusual, just trying to be consistent. The Glastar pages spec one drill size and hardware set, the TWTT Sportsman pages spec another drill size and different hardware set. After ransacking my inventories looking for parts, finally redrilled the braces to #10 and used that set of hardware. Forward bracing, and center stack bracing now completed. Then retightened the lower cross cage tube to lower panel strut which is not easy to get to. Now need to install the right side and left side accessory panels which should be easy. Will use adel clamps in lieu of welded mounting tabs.

  Oct 26, 2023     Center Radio Stack Brace - (3.55 hours)       Category: Instrument Panel

Fabricated a central cantilever brace for the readio stack; while newer kits assume a welded tab in the panel crossbar, my kit did not have one. Used an adel clamp instead. This of course required a trip to Wipaire at SSP to buy an assortment of adel clamps, and also some inset machine screw sizes.

Also a good excuse to chat with a friend at Aerotronics, confirming the screw (inset 6-32) that fits the Garmin chassis.

  Oct 25, 2023     Set the panel vertical - (3.5 hours)       Category: Instrument Panel

Completed fabrication of the new panel top-support braces, dialed in the degrees relative to the waterline, and drilled, therein setting the panel vertical. Very pleased to realize that the Sportsman approach to the hardware (which I've used) was an improvement over the original Glastar hardware shown in the Glastar manual pages.

Had to unscrew the key/ignition unit when mounting the panel in the cage. Contacts the cage frame pipe. See photos. Also spoke to Aerotronics, and I can easily move the key hole in the left small "ignition/accesories" panel faceplate to creat additional space for clearance behind the panel relative to the cage frame.

Mocked up the center radio support bracket, and will fabricate it tomorrow.

  Oct 24, 2023     Progress on instrument panel frame mounting - (4.9 hours)       Category: Instrument Panel

Prior kit owner had fabricated the two top panel support brackets....unfortunately upside down and/or reversed left/right. Considered reworking, but they were also the wrong length...or maybe were done for a 3rd party panel frame I chose not to use. Conclusion: fabricate new brackets. Did the fabrication and grinding, now just need to verify length prior to drilling mounting holes.

Lesson learned...moved the entire panel up and out of harms way to grind off the 2nd unused tab that intereferes with the wiring. Also smoothed the residual lip from the 1st tabs removal. Also ground a curve at the base of the two vertical fiberglass braces for better fit.

Installed the 4 screws/hardware for the lower rail of the panel. Tricky but got it done.

Note: Had to remove the ignition key as the current mount places the rear too close/in contact with a cage tube. Follow up required.

  Oct 23, 2023     Panel lines up - (2 hours)       Category: Instrument Panel

Success. Realized that tilting the panel from the top into the cabin (ie closer to 90 degrees) creates more lateral adjustment space. And also trimmed flat the base of the two vertical fiberglass posts. Holes finally line up.

Will remove 2nd interfering tab, and do a bit more fiberglass trimming before hard installation of lower tabs.

  Oct 21, 2023     Close but no cigar - (1.9 hours) Category: Instrument Panel

Trimming and stretching....getting closer to hole-lineup, but not there yet.

  Oct 20, 2023     Instrument Panel Installation with Chris - (1.5 hours) Category: Instrument Panel

Visiting son-in-law too good an opportunity for a 2nd set of hands, and we made fast work of getting the panel inside the cage. Got instrument panel loosely in place, and then ran Chris back home. Then returned for putting hardware in place, but cage tab holes and panel bracket holes are not lining up. Also 2 of the 6 lower mounting tabs interfere with switch wiring. Ground off one of the interfering tabs, but unfortunately nicked one of the wire bundles going to the Nav lights switch. Will need to splice in new wires before final hard mounting of the panel.

Trimmed a bit of the panel fiberglass. Also aired the tires to 40 psi for both nose and mains, and measured the waterline at .9 degrees on left, and 1.1 degrees on right (nose a bit low.) Will use the angle for setting the vertical position of the panel relative to the airframe.

  Oct 19, 2023     Panel guts - (3 hours)       Category: Instrument Panel

Removed the rest of the radios from the panel for security and safekeeping during the build, and also makes the panel frame lighter for the installation. Spent lots of time measuring the attached accessory panel which goes into the space first. As compared to later kits, mine does not have the grounding tabs welded in place, and studied/mused/reviewed several ways to eventually handle it. Man'ana is becoming a favorite word.

  Nov 18, 2022     Pitot link in the wing - (2.2 hours)       Category: Instrument Panel

Decided to redo/re-fabricate the tubing link from the pitot tube in the wing to the red tubing going over to fuselage.
MUCH easier/quicker to redo than the initial part fabrication. The tricky part is easy if you know about it....there is a 3/4 inch length minimum needed to use the flaring tool. And of course a minimum for the tube bender. And of course another minimum for the cutter. Easy-Peasy now! (the old one was ok, just oversized).

  Jul 22, 2022     Installing nut plates in instrument panel mounting flange - (3 hours) Category: Instrument Panel

Countersunk all rivet holes for nut plates. Packed shell and support bracket to take to Airventure and pass to Aerotronics.

  Jul 21, 2022     Panel skeleton progress - (5 hours)       Category: Instrument Panel

Located the old instruction sheets for the Hammershead panel. Fit the new panel skeleton frame to the old cross bracket, and drilled the new panel skeleton. Installed 8 nut plates across the bottom of the panel/bracket. Measured the vertical 90 degrees for preliminary fit.

  Jul 20, 2022     Frame fitting - (3 hours) Category: Instrument Panel

Received the previously owned new panel frame from Glasair. Worked with the cross panel L-bracket prior builder fabricated for the Hammershead panel.

  May 25, 2022     Located & Analyzed Current Instrument Panel & Glareshield - (3 hours) Category: Instrument Panel

Ordered instruments, all Garmin, from Aerotronics. Discussion regarding the fiberglass panel and glareshield currently in my inventory, which I will not be able to use. Likely have to grind off the vertical tabs of the crossbar frame.

Fabricated the support brackets for mounting the conduits in each wing, currently laying loose in place.

  Aug 25, 2021     Removal of fiberglass panel and brackets - (3 hours) Category: Instrument Panel

Removed fiberglass panel I don't intend to use and associated brackets.
Pulled brake lines (plastic) which were installed. Planning to upgrade to metal lines.